t.o. 33d9-17-89-1wla.1-s.es/us-minuteman-fa820408q50338-technical-manual... · 2014-06-09 · this...

T.O. 33D9-17-89-1TECHNICAL MANUAL

INTERMEDIATE MAINTENANCE INSTRUCTIONS

GUIDANCE SECTION

COOLER TEST REPAIR SET

PART NO. 25-33383-173

A/E47T-23

BOEINGF42600-82-G-7501F42600-90-D-0457F42610-98-C-0001

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specificauthority of the Department of the Air Force of the United States; it will be used for military purposes only; individual or corporate rights originatingin the information, whether patented or not, will be respected; the recipient will report promptly to the United States any known or suspectedcompromise; and the information will be provided substantially the same degree of security afforded it by the Department of Defense of theUnited States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of theoriginating United States agency.

DISTRIBUTION STATEMENT: Distribution authorized to US Government Agencies and their contractors for administrative and operational useas of 26 January 1984. Other requests for this document shall be referred to 526 ICBMSG ⁄ ENV, Hill AFB, UT 84056-5816.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, etseq) or the Export Administration Act of 1979, as amended, (Title 50, U.S.C. App. 2401, et seq). Violations of these export laws are subject tosevere criminal penalties. Disseminate in accordance with the provisions of AFI 61-204.

HANDLING AND DESTRUCTION NOTICE: Comply with distribution statement and destroy by any method that will prevent disclosure of thecontents or reconstruction of the document.

Published under authority of the Secretary of the Air Force

22 FEBRUARY 2005 CHANGE 3 2 APRIL 2008

Basic and all changes have been merged to make this a complete publication.

A paged to chg-3.

Dates of issue for original and changed pages are:

Original . . . . . . . . . 0 . . . . . 22February 2005 Change. . . . . . . . . 2 . . . . . . . . 5July 2006Change . . . . . . . . . 1 . . . . . . . 29June 2006 Change. . . . . . . . . 3 . . . . . . . 2April 2008

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 96 CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *ChangeNo. No. No. No. No. No.

Title . . . . . . . . . . . . . . . . . . . . 3A . . . . . . . . . . . . . . . . . . . . . . 3i . . . . . . . . . . . . . . . . . . . . . . . 2ii - viii . . . . . . . . . . . . . . . . . . 01-1 - 1-3 . . . . . . . . . . . . . . . . . 01-4 Blank. . . . . . . . . . . . . . . . . 02-1 - 2-3 . . . . . . . . . . . . . . . . . 02-4 Blank. . . . . . . . . . . . . . . . . 03-1 - 3-4 . . . . . . . . . . . . . . . . . 04-1 - 4-14. . . . . . . . . . . . . . . . 05-1 - 5-7 . . . . . . . . . . . . . . . . . 05-8 . . . . . . . . . . . . . . . . . . . . . 15-8.1 Added. . . . . . . . . . . . . . . 15-8.2 Blank . . . . . . . . . . . . . . . 15-9 - 5-11 . . . . . . . . . . . . . . . . 05-12 . . . . . . . . . . . . . . . . . . . . 35-12.1 Added. . . . . . . . . . . . . . 35-12.2 Blank. . . . . . . . . . . . . . . 35-13 - 5-14. . . . . . . . . . . . . . . 05-15 . . . . . . . . . . . . . . . . . . . . 35-16 . . . . . . . . . . . . . . . . . . . . 05-17 . . . . . . . . . . . . . . . . . . . . 15-18 - 5-21. . . . . . . . . . . . . . . 05-22 . . . . . . . . . . . . . . . . . . . . 15-23 - 5-40. . . . . . . . . . . . . . . 05-41 . . . . . . . . . . . . . . . . . . . . 25-42 - 5-43. . . . . . . . . . . . . . . 05-44 Blank. . . . . . . . . . . . . . . . 0FP-1 . . . . . . . . . . . . . . . . . . . . 0FP-2 Blank. . . . . . . . . . . . . . . . 0FP-3 . . . . . . . . . . . . . . . . . . . . 0FP-4 Blank. . . . . . . . . . . . . . . . 0FP-5 . . . . . . . . . . . . . . . . . . . . 0FP-6 Blank. . . . . . . . . . . . . . . . 0FP-7 . . . . . . . . . . . . . . . . . . . . 0FP-8 Blank. . . . . . . . . . . . . . . . 0FP-9 . . . . . . . . . . . . . . . . . . . . 0FP-10 Blank. . . . . . . . . . . . . . . 0FP-11 . . . . . . . . . . . . . . . . . . . 0FP-12 Blank. . . . . . . . . . . . . . . 0

T.O. 33D9-17-89-1

LIST OF EFFECTIVE PAGESINSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line inthe outer margin of the page. Changes to illustrations are indicated by shadedor screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

USAFA Change 3

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

1 INTRODUCTION AND GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2.1 Test Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 SPECIAL TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 Alternate Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.3 Tools and Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

3 PREPARATION FOR USE AND SHIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1 Shipping and Storage Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1.1 Vacuum Manometer Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 Preparation For Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.1 Refrigerant Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.2 Photoelectric Controller Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.3 Manometer Gauge Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.4 Ground Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.2.5 Electrical Power and Compressed Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.2.6 Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3 Preparation For Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3.1 Manometer Tube Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3.2 Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4 OPERATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1 Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.1 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.2 Coolant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.3 Purge Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.4 Compressor Air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.1.5 Control Valve Testing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.1.6 Evacuation and Refrigerant Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34.2.1 Preoperational Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.1.1 Component Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-415.3.1 Coolant Supply and Filter Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-415.3.2 Refrigerant Supply Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-425.3.3 Vacuum Pump Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-42

T.O. 33D9-17-89-1

TABLE OF CONTENTS

Chapter Page

Change 2 i

5.4 Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-435.4.1 Tubing Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-435.4.2 Measuring Tube Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-435.4.3 Digital Panel Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-43

T.O. 33D9-17-89-1

TABLE OF CONTENTS - Continued

Chapter Page

ii

1-1 Guidance Section Cooler Test Repair Set A/E47T-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22-1 Nitrogen Adapter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32-2 Test Stand Used with A/E47T-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33-1 Manometer and Sealing Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24-1 Left Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44-2 Control Valve Driving Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74-3 Right Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85-1 Test Repair Set Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2FO-1 Electrical Schematic - Left Side of Test Bench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FP-1FO-2 Plumbing Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FP-3FO-3 Electrical Schematic - Right Side of Test Bench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FP-5FO-4 Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FP-7FO-5 Electronic Enclosure Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FP-9FO-6 Airflow Checkout Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FP-11

T.O. 33D9-17-89-1

LIST OF ILLUSTRATIONS

Number Title Page

iii

1-1 Table of Leading Particulars. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-2 List of Consumable Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32-1 Special Tools and Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24-1 Preoperational Checkout - Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114-2 Preoperational Checkout - Right Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-135-1 Power Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75-2 Control Valve Driver Circuit Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-105-3 Coolant System Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-125-4 Air Regulation Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-155-5 Refrigeration Controls Checkout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-195-6 Power Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-285-7 Control Valve Driver Circuit Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-305-8 Coolant System Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-315-9 Air Regulation Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-345-10 Refrigeration Controls Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-35

T.O. 33D9-17-89-1

LIST OF TABLES

Number Title Page

iv

SAFETY SUMMARY

GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes, which could cause injury or death to personnel, or damage toequipment if not properly followed. This safety summary includes general safety precautions and instructions that must beunderstood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior toperforming any task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be reviewed and understood.

WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in the manual to highlight operating or maintenance procedures, practices, conditions,or statements, which are considered essential to protection of personnel (WARNING) or equipment (CAUTION). WARNINGsand CAUTIONs precede the step or procedures to which they apply. WARNINGs and CAUTIONs consist of four parts:Heading (WARNING and CAUTION), a statement of the hazard, minimum precautions, and possible result if disregarded.NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements that arenot essential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending uponthe information to be highlighted. The headings used and their definitions are as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement,etc., which, if not strictly observed, could result in injury to, or death of, personnel or longterm health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement,etc., which, if not strictly observed, could result in damage to, or destruction of, equipmentor loss of mission effectiveness.

NOTEHighlights an essential operating or maintenance procedure, practice, condition or statement.

HAZARDOUS MATERIALS WARNINGS.

Hazardous material WARNINGs in this manual are used to warn personnel of Personal Protective Equipment (PPE),ventilation, fire and other hazards. If the PPE for the hazardous material has changed (ref. product MSDS) consult with BaseBioenvironmental Engineering to determine if the current T.O. PPE is adequate. If the PPE is not adequate, notify 20AF/LGM.

Hazardous Materials Description.

The following hazardous materials are used in this manual:

HFC (R134A) is an asphyxiant and contains chlorofluorocarbon (CFC). Use in a well-ventilated area. Respiratory protectionis not normally required in well-ventilated area, but dense vapors in confined spaces displaces breathing air causingasphyxiation. Protective clothing should minimize exposed skin. Wear cloth-lined rubber gloves and goggles plus faceshield.Liquid coming in contact with the skin could cause frostbite. Treat frostbite by applying warm water to the affected area.

Dry lubricant is toxic and hazardous. Wear neoprene or mylar gloves and chemical goggles. Use in a well-ventilated area.

High vacuum sealant is toxic and hazardous. Wear impervious gloves and safety glasses. Use in a well-ventilated area.

T.O. 33D9-17-89-1

v

Refrigerant compressor oil is a skin and eye irritant. Wear rubber or nitrile gloves and chemical workers goggles to preventeye/hand contact. Use in a well-ventilated area. If contact with skin occurs, wash affected area with soap and water. If contactwith eyes occurs, do not rub. Flush eyes with water for at least 15 minutes while holding upper and lower eyelids open toensure complete cleansing. Wash hands with soap and water after handling oil. Keep away from excessive heat, sparks, andopen flames.

Armstrong 520 adhesive is flammable and toxic. Use in a well-ventilated area. Excessive skin contact could cause drying andcracking of skin and dermatitis. Wear chemical-resistant gloves and chemical workers goggles/faceshield to prevent eye/handcontact. Wash hands with soap and water after handling. Keep away from excessive heat, sparks and open flames.

Sodium chromate is caustic, corrosive, and toxic. Respiratory protection is not required where adequate ventilation exists.Wear neoprene gloves and safety goggles/faceshield, cotton coveralls with sleeves extended into gloves, and an apron shallbe worn over the coveralls. Check to see that all parts of the body are covered. Use in a well-ventilated area. If dusty situationsprevail, work in ventilation hood or wear NIOSH-approved dust respirator or mask. If inhaled, remove to fresh airimmediately. If contact with skin occurs, wash affected area with water immediately. If contact with eyes occurs, do not rub.Flush eyes with water for at least 15 minutes while holding upper and lower eyelids open to ensure complete cleansing; thenget medical aid immediately. Wash after handling and before eating, drinking, or smoking.

A health hazard exists to personnel whenever mercury is spilled and comes in contact with the body. Should a mercury spilloccur, the following health safety actions are required: wear rubber gloves during cleanup, package and dispose through localDPDO office, and contact Bioenvironmental Engineering Organization.

Ultrasonic cleaning detergent is hazardous. Detergent is a skin, eye, and inhalation irritant. Use in a well-ventilated area. Wearrubber gloves and chemical splash goggles. If contact with eyes occurs, do not rub. Flush eyes with water for at least 15minutes while holding upper and lower eyelids open to ensure complete cleansing; if irritation persists, consult a physician.If contact with skin occurs, flush area with water for 15 minutes. Wash hands thoroughly after handling.

SAFETY PRECAUTIONS.

The following safety precautions shall be observed while performing procedures in this manual. (WARNINGs, CAUTIONs,and/or NOTEs will be repeated within this manual.)

Electrical Safety Requirements.

Rubber goods designed for protection of the technician (electrical rubber gloves with leather protective shells and rubber mats)shall be used when working on energized electrical circuits of 50 volts or more. Electrical rubber gloves with leather protectiveshells, rubber mats, and rubber blankets shall be used while testing energized electrical circuits of 600 volts or more. Whenworking adjacent to electrically energized circuits in excess of 600 volts, electrical rubber blankets shall be used to coverenergized equipment. Testing of energized electrical circuits shall only be done while standing on and in contact with drysurfaces. Normal troubleshooting activity involving the operation of switches, the insertion and/or removal of fuses, or testingof exposed conductors on circuits below 600 volts do not require rubber protective goods. When working adjacent to energizedelectrical circuits, the technician shall wear applicable safety equipment or use a rubber blanket when deemed necessary.Detailed information on rubber matting, gloves, and blankets can be found in AFOSH Standard 91-501.

Two people (buddy/buddy) within easy access of each other are required during testing, troubleshooting, or performingmaintenance on energized equipment.

Lockout or tagout devices shall be attached when circuit breakers or switches are opened to perform maintenance.

After removing power from a component, verify no voltage is present prior to performing maintenance.

Actual fuse amperage ratings shall be verified prior to installation/reinstallation.

T.O. 33D9-17-89-1

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Probing Requirements.

Weapon System Specification requirements prohibit direct probing of “in-line launch critical circuits” by organizational levelmaintenance. The use of approved T.O. procedures to include breakout connector adapters and approved testing equipmentmust be strictly followed when fault isolating “in-line launch critical circuits”. Organizational maintenance may use directprobing techniques on nonlaunch critical circuits when approved by specific T.O. procedure. Technical Engineering may usedirect probing techniques on nonlaunch critical circuits to perform fault isolation using schematics and normal testingtechniques with approved testing equipment (appropriate T.O. and/or T.O. 21M-LGM30F-12 listed equipment). TechnicalEngineering will contact OO-ALC/LMEI (SELECT) if there is a question on whether or not a circuit is “in-line launchcritical”.

Manual Lift Requirements.

Maintenance equipment, tools, and replacement components could be awkward and heavy to handle. Consider team liftingwhen items are known to weigh more than 25 pounds. All pertinent lifting factors should be considered when determininglifting requirements (i.e. individual’s strength, distance item is carried, and size and weight of the object). Any object toodifficult to be lifted/carried by one person should be lifted/carried by two or more personnel or use a mechanical lift. A NOTEidentifying the weight of the item to be lifted shall be placed in the procedure just prior to lifting heavy (approximately 60pounds or more) and/or awkward items.

Summary of Warnings.

120-Vac power is present inside cabinet when power cables are connected. Serious shock hazard exists when panels are off.

Pressure is present in the hose. Faceshield and rubber gloves must be used to prevent personnel injury.

120/208 volts of power is present inside test bench. Serious shock hazard exists when panels are removed.

Do not exceed 250-psig pressure when testing PS-1 and TS-1 and make no adjustments except as specified. PS-1 and TS-1are safety devices to protect equipment and personnel.

Summary of Cautions.

When closing test bench manual shutoff valves, the use of excessive force can damage valve seats.

S3 must be set correctly before S2 is operated to prevent damage to control valve motor.

Facility ground wire, electrical cables, and air shall be connected before operating.

Do not leave MEASURING TUBE HEATER switch on when measuring tube is empty.

Initial coolant flow shall not exceed 1.5 pounds per minute until air is forced out of coolant lines. Excessive air flow rate candamage test bench.

COMPRESSOR AIR RETURN FLOW meter shall not be allowed to exceed 2.5 cfm. Failure to comply could result in damageto flow transducer MT4.

Use two wrenches when loosening or tightening fittings to avoid stressing plumbing system.

Failure to set REFRIGERANT MEASURING TUBE HEATER switch to OFF when measuring tube is not in filled conditionwill overheat and damage measuring tube assembly.

CONTROL VALVE switch S3 must be set correctly before connecting control valve and operating OPEN/CLOSE switch S2.

GENERAL SAFETY PRECAUTIONS.

The following general safety precautions shall be complied with throughout this manual. (These precautions willNOT berepeated within the manual.)

Soldering iron is hot and solder could pop/splash. Avoid contact with tip and wear approved eye protection.

Blow drying items may be hazardous to eyes and skin. Wear goggles and ensure pressure is less than 30 psi.

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Cleaning with compressed air can create an eye and/or skin hazard. Wear goggles; ensure air is regulated to less than 30 psiand do not direct the air against skin.

Do not wear metal-type jewelry when working around electronic/electrical equipment.

Shop technicians may work on low voltage circuits (electrical systems of less than 50 volts excluding the MAF and LFbatteries and other high amperage systems), while energized for the purpose of testing, calibrating, troubleshooting, minorrepairs, and replacement of fuses/circuit breakers. Lockout/tagout power sources whenever possible. Comply with applicableAFOSH requirements.

Sodium chromate solution is a hazardous waste. Contact Bioenvironmental Engineering Office for disposal procedures.

Minuteman Base Coding.

Code symbols are used in this manual to show which information is applicable to a particular base or group of bases. Whencode symbols appear in paragraph titles, illustration titles, illustration or procedural steps, the information applies only to thebase(s) represented by the code symbol. Where no coding appears, the information is applicable to all base(s) covered by thismanual. The following code symbols are used:

[1] Wing 1, Squadrons 1 through 3.

[1X] Wing 1, Squadron 4.

< End of coded information where not otherwise obvious

List of Related Publications

Number Title

T.O. 00-20-3 Maintenance Processing of Reparable Property and RepairCycle Asset Control Systems

T.O. 21M-LGM30F-01 List of Applicable Publications, LGM30 Weapon System

T.O. 21M-LGM30F-4-(Series) LGM30F Weapon System Illustrated Parts Breakdown

T.O. 21M-LGM30F-6 Scheduled Inspection and Maintenance Requirements

T.O. 21M-LGM30F-12 Special Maintenance Safety and ElectromagneticInterference Provisions Safety Manual

T.O. 21M-LGM30F-101 Corrosion Control and Treatment

T.O. 21M-LGM30G-2-31 Weapon System Hardness Preservation and InstallationHardware

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CHAPTER 1INTRODUCTION AND GENERAL INFORMATION

1.1 INTRODUCTION.

This manual includes instructions for operation and intermediate level maintenance of the guidance section cooler test repairset A/E47T-23, Part No. 25-33383-173, hereinafter referred to as the test bench. See Figure 1-1. Operation instructions,Chapter 4, briefly describes theory of operation and includes procedures for startup, checkout, and shutdown; however,detailed use of the test bench is described in T.O. 35E9-35-22, Guidance Section Liquid Cooler Maintenance. Maintenanceinstructions, Chapter 5, consists of test bench checkout, troubleshooting, and repair procedures. Special tools and testequipment required for maintenance of the test bench, Chapter 2, are identified by nomenclature, number, and application.Chapter 3 describes preparation of the test bench for use and preparation for shipment.

1.2 GENERAL INFORMATION.

At all Minuteman wings, the test bench is used at the MSB as the checkout and repair facility for the guidance control sectionliquid cooler. The following parts can be individually connected to and operated on the test bench:

a. Coolant Chiller Unit, FRK-2/F37U-9

b. Compressor, part of FRK-2/F37U-9

c. Coolant Pump, PMK-48/F37U-9

d. Control Valve Assembly, VAK-31/F37U-9 (400 Hz)

e. Control Valve Assembly, VAK-36/F37U-22 (DC)

When closing test bench manual shutoff valves, the use of excessive force can damage valveseats.

NOTEBefore removing/replacing components, check for faulty wiring, control air leaks, and otherabnormal conditions using standard maintenance practice.

1.2.1 Test Bench. The test bench features do not include provisions for maintaining the electronic control amplifier,which is tested and repaired according to T.O. 35E9-35-22. The test bench contains a supply of coolant, and it connects tocompressed air which is used for purging coolant from components after test. A vacuum pump and controls are built into thetest bench for evacuation of the chiller. A refrigerant supply cylinder with heater is contained in the rear of the test bench.Driving signals for the control valve assemblies’ motors are electronically generated within the test bench.

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Figure 1-1. Guidance Section Cooler Test Repair Set A/E47T-23

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Table 1-1. Table of Leading Particulars

Guidance Section Cooler Test Repair Set

Width 66.125 inches

Height 69.875 inches

Depth 44.0 inches

Weight 1000 pounds approximately

Input electrical service a. 208/120 Vac 60 Hz 3Ø 20 amps

b. 208/120 Vac 400 Hz 3Ø 10 amps

Input compressed air 100 psi

Table 1-2. List of Consumable Materials

Item Identification Application

Refrigerant HFC134a To refill 125-pound test bench cylinder.

High vacuum sealant 3M Weatherban 606-NF WhiteAcrylic Sealant or equivalent

To seal refrigerant and vacuum connections.

Pipe joint sealing tape 3M Teflon Tape Type B or equiva-lent

For assembly of pipe thread tubing fittings.

Dry lubricant Miller Stephenson MS122N/CO2,NSN 9150-01-390-1408,or MS-122B (replacement)

For assembly of straight thread tubing fittings.

Adhesive Armstrong type 520 or equivalent For installation of refrigerant measuring tube heatingelements.

Vacuum pump oil Super X/Flushing High VacuumPump Oil 5000 or equivalent

For refilling vacuum pump.

Ultrasonic cleaningconcentrate detergent

MICRO-10 7930-01-300-3536 orequivalent

Used in ultrasonic cleaner.

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CHAPTER 2SPECIAL TOOLS AND TEST EQUIPMENT

2.1 GENERAL INFORMATION.

This chapter lists the test equipment and special tools for performing checkout, troubleshooting, adjustment, and repairprocedures of the cooler test repair set.

2.2 ALTERNATE EQUIPMENT.

If the primary electrically-powered tool, test equipment, or item is not available, an approved alternate may be used. AlternateAir Force standard test equipment and tools may be used as follows:

NOTEOnly government furnished equipment used for official government business will beevaluated for approval as exempt power devices (refer to T.O. 21M-LGM30F-12).

a. Except when specifically designed test equipment is called for or when nuclear certified test equipment is requiredper the Master Nuclear Certification List (MNCL) and alternate items are not listed therein, or when the table forsupport equipment does not authorize the use of an alternate or equivalent item/substitute.

NOTEElectromagnetic Interference (EMI) and Electromagnetic Compatibility (EMC) may haveadverse effects on weapons system equipment or ordnance items. Weapon System Specifi-cations and MIL-STD-461 requirements must be complied with during the selection processfor identifying alternate electrically-powered tools, items, and test equipment.

b. Any substitute identified by the Test Measurement and Diagnostic Equipment (TMDE) branch, Technical Engi-neering (TE), or items identified by the USAF Interchangeability and Substitution (I&S) group stock list shall beforwarded to 20AF/LGM for approval. 20AF shall forward the request to OO-ALC/LME for final evaluation andapproval.

c. The same authority may be exercised by TE for all other equipment and special tools. Extreme care shall be usedin selection and use of substitute (alternate) equipment to ensure weapon system or equipment degradation doesnot result from the use of the substitute.

2.3 TOOLS AND TEST EQUIPMENT.

The tools and test equipment used in this technical manual are listed in Table 2-1. Common hand tools required for the jobare not listed.

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Table 2-1. Special Tools and Test Equipment

Nomenclature Designation Purpose

Multimeter, Digital 6625-00-005-1233 or equivalent Voltage, resistance, and continuity measuring.

Oscilloscope withHP181A dual channelamplifier

6625-00-477-3616 or equivalent Modulating control valve motor driving waveformmeasuring.

Ammeter, clamp-on type 6625-00-649-0411 or equivalent Checkout of 400 Hz POWER AMPERAGE meter.

Frequency Counter,SAMME120

6625-00-165-2129 or equivalent Checkout of 400 Hz POWER FREQUENCY meter.

Nitrogen Bottle, chargedwith 250 psig or greaterdry nitrogen

-- Various pressure and flow tests.

RegulatorAssembly-CompressedGas

4820-01-018-9604 or equivalent Nitrogen pressure control.

Nitrogen AdapterAssembly

Locally manufactured See Figure 2-1 Connects regulator to test bench.

Test Stand used withA/E47T-23

Part No. 25-79824-1 Calibration standard for checkout and adjustment oftest bench meters.

Pressure Vessel, onecubic foot capacity, withshutoff valve and 10-inchlength of 1/4-inch ODtubing attached

Use empty commercial 15-pounddisposable freon cylinder or equivalent

Checkout of test bench charging controls.

Phase Meter Phase Sequence Indicator, Avtron T4706625-00-914-1022 or equivalent

Check for proper connection of 400 Hz powercable.

Halogen Leak Detector 4940-00-856-9690 or equivalent Test for refrigerant leaks.

Printed Circuit BoardPuller

MX-3626 Removal and installation of circuit board inelectronic enclosure.

Connector Adapter Set AN/GSM-94(V) Checkout of 400 Hz power.

Shorting Plug Assembly TRW Cinch-Jones P-304-AB withjumper wire between pins 1 and 2

Checkout of refrigerant pressure switch PS-2.

Tee, tube to swivel,swivel on run

4730-00-719-2600 or equivalent Air regulator checkout.

Ultrasonic Cleaner 4940-01-084-4196 Used for cleaning stainless steel filter element.

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Figure 2-1. Nitrogen Adapter Assembly

Figure 2-2. Test Stand Used with A/E47T-23

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CHAPTER 3PREPARATION FOR USE AND SHIPMENT

3.1 SHIPPING AND STORAGE REQUIREMENTS.

The test bench motions, such as those encountered during shipping or warehouse handling, require the following items to beremoved and packaged separately:

a. Refrigerant cylinder (Figure 5-1, 76).

b. Cylinder band heater, including pressure switch PS-1 (74) and temperature switch TS-1 (75).

c. Photoelectric controller PEC-1 (56).

d. Photoelectric controller PEC-3 (55).

e. All cable, hose, adapter, and test assemblies that are part of the test bench and normally stored in the test benchdrawers. See Figure 1-1.

f. The test stand assembly, Figure 2-2.

3.1.1 Vacuum Manometer Gauge. In addition, the tube sealing mechanism shall be installed in the vacuum manometergauge, Figure 3-1, and all water shall be drained from test bench and test stand. Side panels, front door, and drawers shall besecured in place.

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Figure 3-1. Manometer and Sealing Mechanism

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3.2 PREPARATION FOR USE.

If test bench has been transported, verify receipt of all packages. Remove packaging, inspect for damage, and check itemsagainst shipping list. Verify that items listed in Paragraph 3.1 are included, and place items in Paragraph 3.1, step e, into thetest bench drawers.

3.2.1 Refrigerant Cylinder Installation.

a. Install the band heater assembly onto the cylinder. Position the heater just above the cylinder base with the pres-sure switch aligned to the approximate direction of the refrigerant valve outlet. Snap the band clamp closed.

b. Put the blanket in place on the cylinder.

c. Put the cylinder in the test bench and align the refrigerant valve outlet approximately toward the rear cabinetcenterpost.

d. Install refrigerant pressure indicator assembly onto refrigerant valve outlet with indicator and liquid eye towardthe rear.

e. Install one red hose to shutoff valve V7 (Figure 5-1, 78) and to end connector of refrigerant pressure indicatorassembly.

f. Install the other red hose to side connector of refrigerant pressure indicator and to pressure switch (74).

g. Connect the cable, part of (74), to J108 (58).

3.2.2 Photoelectric Controller Installation.

NOTEThe two photoelectric controllers are identical.

a. Insert one photoelectric controller (PEC-3) into J101 (Figure 5-1, 55).

b. Insert the other photoelectric controller (PEC-1) into J102 (56).

c. Verify that cables are connected to J103 through J113. If a cable is disconnected and its connector marking is notlegible, refer to FO-4 for identity.

3.2.3 Manometer Gauge Preparation. The manometer U-tube is fitted with a tube sealing mechanism, Figure 3-1,which prevents mercury spillage during shipping or handling. The mechanism must be removed before the gauge can function:

a. At rear of panel, disconnect vacuum line at top of manometer and remove mounting nuts. Front scale must beremoved to access bolt heads.

b. Remove wingnut, gauge head, and two neoprene gauge head gaskets from manometer.

c. Remove coil spring and washer from tube sealing mechanism. Grip end of threaded rod and back off plunger nutabout 1/4 inch to reduce expanding washer at bottom end of rod.

Potential mercury hazard exists. Be careful not to break the manometer U-tube. Failure tocomply may result in personnel injury.

d. Carefully remove the sealing mechanism from the U-tube, avoiding entrainment of mercury.

e. Reassemble and reinstall manometer.

f. Store tube sealing mechanism in test bench drawer for future use.

3.2.4 Ground Connections. The test bench has two ground studs, either of which may be used. Connect facility groundto external ground stud on top or the one on the back, whichever is most convenient.

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3.2.5 Electrical Power and Compressed Air.

a. Set the following circuit breakers on test bench to OFF:

400 Hz POWER CB2

60 Hz POWER CB1

60 Hz POWER CB4

b. Connect test bench cables to facility electrical power.

c. Close AIR PURGE valve and connect facility air to test bench.

3.2.6 Checkout. Proceed to Chapter 5.

3.3 PREPARATION FOR SHIPMENT.

The following procedure will prepare the test bench for transportation.

a. Disconnect the power cables, ground wire, and air hose.

b. Remove the right-rear panel.

c. Disconnect both hoses from the refrigerant pressure indicator assembly. Remove the pressure indicator assemblyand both hoses from the test bench.

d. Disconnect pressure switch cable (Figure 5-1, 74) from J108 (58), and remove cylinder from test bench.

e. Remove blanket and band heater assembly from the cylinder.

f. Remove photoelectric controllers (55 and 56) from test bench.

3.3.1 Manometer Tube Sealing.

a. Locate tube sealing mechanism (Figure 3-1), normally stored in test bench drawer, and verify plunger nut isbacked off enough so expanding washer is not compressed.

Potential mercury hazard exists. Be careful not to break the manometer U-tube. Failure tocomply may result in personnel injury.

b. Remove manometer by disconnecting vacuum line and two mounting nuts at rear of panel. Front scale must beremoved to access bolt heads.

c. Remove wingnut, gauge head, and two neoprene head gaskets from manometer.

d. Very slowly insert sealing mechanism into right-hand leg of U-tube until it barely contacts mercury.

e. Grip end of threaded rod and tighten plunger nut until expanding washer very snugly seals U-tube.

f. Install coil spring washer, coil spring, two head gaskets, gauge head, and wingnut. Reinstall manometer.

3.3.2 Packing. Remove assemblies from test bench drawers. All items in Figure 1-1 should be accounted for. These items,special tools in Table 2-1, and items removed in Paragraph 3.3, steps c through f, are ready for packaging. Reinstall rear panelof test bench, secure drawers, door, and side panels, and bench is ready for packaging. Package and transport in accordancewith applicable procedures.

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CHAPTER 4OPERATION INSTRUCTIONS

4.1 THEORY OF OPERATION.

The test bench connects to facility electrical power and compressed air within the repair shop, and operation requires the testequipment listed in Chapter 2. The test bench is otherwise self-contained since it has water and refrigerant storage tanks, andit includes all necessary cables. Refer to schematics FO-1 and FO-2 and to control panel, Figure 4-1, for the followingparagraphs.

4.1.1 Electrical Power. See FO-1. Two electrical cables enter the top of the cabinet and connect to terminal blocks.Facility ground connects to a terminal atop the cabinet. One cable carries 60 Hz, 3-phase power which is routed through linefilter FL1 and CB1 to the following:

a. COOLANT PUMP switch S1, which controls power to the pump motor and to the heater control panel A1. A1receives 208 volts from phases A and B, and it controls the coolant temperature in the tank.

b. Circuit breaker CB3 in left side of cabinet, which controls input power to two dc power supply modules PS1 andPS2. These power supplies provide the necessary dc voltages to the electronic enclosure located above PS2.

c. Coolant and compressed airflow transducer interface assemblies A2 and A3.

d. All electronic digital meters M1 through M10.

e. 60 Hz POWER indicators and ac POWER outlet.

4.1.1.1 Phase Motor. The other cable carries 400 Hz, 3-phase power which is routed through line filter FL2 and CB2;the 400 Hz POWER indicators come on when CB2 is set to ON. The 400 Hz power passes through the variable transformerT1, which controls voltage amplitude, and then through the PHASE MONITOR switch S4 to J1. Connector J1 supplies powerto the chiller, refrigerant compressor or coolant pump under test. The PHASE MONITOR switch selects each phase of 400Hz power for frequency, voltage, and current readout on meters M8, M9, and M10. Meter M10 requires a current transformerT2 (electronic transducer) to match the line to the ammeter circuit.

4.1.2 Coolant System. See FO-1 and FO-2. The coolant system includes:

a. A tank fitted with a drain cock and a 240V 2000W immersion-type heater.

b. Temperature sensor RT1, which is monitored by an adjustable thermostat in the heater control panel A1, which inturn controls the heater.

c. Centrifugal pump, driven by a 120V 60 Hz motor.

d. COOLANT PUMP switch that controls power to pump motor and heater control panel.

e. Coolant filter and a manual supply valve V3, to adjust flow to chiller or control valve under test.

f. Two coolant supply line transducers RT3, MT3, which sense temperature and pressure for display on meters M6and M7, respectively, when a control valve or entire chiller is being tested.

g. Three return line transducers RT2, MT2, and MT5 and meters M3, M4, and M5 which, respectively, sense anddisplay temperature, pressure, and flow of coolant from unit under test. The flowmeter M5 requires linearizer A2to match it to transducer MT5.

4.1.2.1 Coolant Supply. The chiller unit is tested by connecting it to 400 Hz power at J1 and to the coolant supply andreturn lines. Coolant supply temperature and flow rate are adjusted as specified, and return temperature is compared withspecification. A coolant pump to be tested is mounted on top of the coolant tank connected to COOLANT IN and connectedto 400 Hz power at J1. The coolant return flow is adjusted as specified and the return pressure is compared with specification.ac and dc modulating control valves to be tested are connected to COOLANT OUT, COOLANT IN, and electrical connectorJ2. Coolant return flow is compared to specifications when control valve is operated to fully open and to fully closed states.

4.1.3 Purge Air. See FO-1 and FO-2. Facility air from the inlet on top of the cabinet is reduced in pressure by a 20 psigregulator and routed through shutoff valve V4 to the PURGE SUPPLY connector on the control panel. The air is used to purgecoolant from a chiller unit or a modulating control valve after test. When testing is completed on a chiller or control valve,the hoses are disconnected at the panel from COOLANT IN and COOLANT OUT fittings, and they are connected to PURGESUPPLY and PURGE RETURN. Then AIR PURGE manual valve V4 is opened to force residual coolant to return to the tank.

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4.1.4 Compressor Air. See FO-1 and FO-2. The compressor air originates from the compressor under test and enters thecontrol panel at the COMPRESSOR AIR RETURN fitting. The system includes a drain valve, relief valve, and an oil separatorwhich removes compressor oil from air being discharged inside the cabinet. Flow transducer MT4, range extender amplifierA3, and FLOWmeter M2 provide monitoring of compressor discharge. COMPRESSOR AIR RETURN manual valve V1 isused to restrict flow so compressor discharge pressure can be monitored by transducer MT1 and PRESSURE meter M1.

4.1.5 Control Valve Testing System. Coolant is connected and controlled as described above, and coolant return flowis monitored by transducer MT5, linearizer A2, and FLOWmeter M5 during control valve operation. Driving signals for acand dc modulating control valves, Figure 4-2, FO-1 and FO-5, are generated by independent signal generators within theelectronic enclosure. Power supply modules PS1/PS2 provide input power to the circuits, and CONTROL VALVE switch S3enables the selected signal generator. Switch S3 also selects the desired signal generator output. CONTROL VALVEOPEN/OFF/CLOSE switch S3 controls the sequence of pulses generated by the dc signal generator, and it controls the inputsto both control valve types. Capacitor C20 shifts current phase for ac valve motor operation. Testing a control valve requiresprior setting of S3 to prevent damaging the control valve motor. Connector J2 is the electrical input to both control valve types.When driving signals are applied to a dc valve, indicators DS5, DS6, DS7, and DS8 flicker in sequence, indicating drivingsignals are present and in correct order. When driving signals are issued to a 400 Hz valve, indicator DS3 or DS4 flickers toindicate that the driving signals are present and are switched to the correct motor winding.

4.1.6 Evacuation and Refrigerant Charging System. See FO-2, FO-3, and Figure 4-3. A chiller unit is charged by firstevacuating it to a sufficiently low pressure and then allowing it to draw in a measured volume of refrigerant. Controls andgauges for testing, evacuating, and charging the chiller unit are on the right-hand panel. Inside the test bench are the wiring,plumbing, valves, vacuum pump, and refrigerant cylinder. A circuit breaker, 60 Hz POWER CB4, controls power to the entireevacuation and refrigerant charging system. The PANEL POWER switch, TGS-2, switches the 60 Hz, phase C to all systemcomponents except the vacuum pump; thus the pump can run when only CB4 and VACUUM PUMP switch TGS-1 are turnedon. The vacuum pump evacuates the chiller, and when the pump is turned off, the vacuum break, solenoid valve SOL-B, opensto vent the pump suction preventing oil from being drawn into the chamber.

4.1.6.1 Evacuation. With VACUUM PUMP switch ON and function switch RSS-2 set to EVACUATE, solenoid valvesSOL-V/V8 and SOL-P/V9 energize/open to evacuate chiller in preparation for either pressure testing or charging. Vacuumpressure can initially be monitored on the mercury manometer in both barometric and absolute. Higher vacuum pressure inmillimeters of mercury, absolute (mm Hg, abs.), is monitored on the panel gauge. Since 1 inch = 25.4 mm and 1 mm = 1000microns, a refrigerant charging vacuum of 100 microns Hg absolute is a relatively low pressure (high vacuum).

4.1.6.2 Charging. Prior to charging the refrigerant unit with refrigerant, the correct volume of refrigerant is filled into themeasuring tube, and since volume is affected by temperature, the refrigerant temperature in the cylinder and measuring tubeis controlled. The CYLINDER HEATER switch TGS-3 and MEASURING TUBE HEATER switch TGS-4 are turned on, andthe TUBE HEATER indicator comes on until the correct pressure is attained. The CYLINDER HEATER indicator comes onbut will cycle after pressure is attained. At operating pressure, PRESSURE switch PS-2 closes, energizing relay CR-H to turnoff the tube heater and to enable the charging circuits. Now, when the REFRIGERANT MEASURING TUBE switch RSS-1is momentarily set to FILL, relay CR-F closes to energize/open solenoid valve SOL-F/V11, allowing refrigerant to flow intothe measuring tube. When the tube is nearly full, the upper photoelectric detector/controller valve, PD-1/PEC-1, opens CR-Fto close SOL-F/SOL-E to stop the flow. With RSS-2 set to CHARGE, RSS-1 can be momentarily set to CHARGE to closerelay CR-C, to energize/open solenoid valve SOL-C/V10, transferring refrigerant from measuring tube to chiller unit byvacuum pressure. The lower photoelectric detector/controller, PD-3/PEC-3, opens CR-C to close SOL-C/V10 to stop the flowafter the measured volume has been transferred.

4.1.6.3 Gas Ballast and Purge. The GAS BALLAST valve V17 slightly vents the vacuum pump ahead of the dischargevalves to reduce the exhaust pressure change; therefore, reducing or eliminating water condensation within the pump. Waterin the vacuum pump causes oil emulsification, reduced efficiency, and discharge valve noise. However, since the ballast gas(air), at atmospheric pressure, is entering the pump chamber too much gas ballast can make it impossible to attain a very lowpressure such as 100 microns Hg, abs.

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4.2 OPERATION.

Operational procedures for the test bench, during the testing and maintenance of the G&C chiller unit or its components, aredescribed in T.O. 35E9-35-22.

Facility ground wire, electrical cables, and air shall be connected before operating. Failureto comply may result in equipment damage.

4.2.1 Preoperational Checkout. Ensure facility ground wire, electrical cables, and air are connected. Check the drawerfor the cable and hydraulic hose assemblies needed for OGE testing. Perform the preoperational checkout procedures, Table4-1 or Table 4-2, as required, to be sure bench is operational. If any steps of the preoperational checkout fail, proceed tomaintenance instructions in Chapter 5.

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Figure 4-1. Left Control Panel (Sheet 1 of 3)

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No. Control/Indicator Function

1. COOLANT HEATERCONTROL (A1)

Potentiometer Adjusts temperature of water in coolant tank.

Indicator On during heater-on cycle.

Switch Controls power to heater controls when CB1 and S1 are on.

Fuse - 15 amp Protects circuitry in heater control panel (A1).

2. AIR PURGE

Valve (V4) Controls air to PURGE SUPPLY fitting.

PURGE SUPPLY fitting Connects to chiller unit or control valve to be purged of coolant.

PURGE RETURN fitting Returns purged coolant to tank.

3. COOLANT SUPPLY

TEMPERATURE meter (M6) Displays temperature of coolant to chiller unit or control valveunder test.

PRESSURE meter (M7) Displays coolant pressure at input of unit under test.

COOLANT PUMP S1 switch andindicators

Switch controls 120 volts to pump and 208 volts to heater control.Indicators are on the two phases of 208 volts.

Valve (V3) Controls coolant supply flow when pump is running.

COOLANT OUT fitting Input to chiller unit or control valve under test.

4. COOLANT RETURN

TEMPERATURE meter (M3) Displays temperature of coolant from chiller unit or control valveunder test.

PRESSURE meter (M4) Displays coolant pressure at output of unit under test.

FLOW meter (M5) Indicates coolant flow rate through unit under test.

Valve (V2) Used to control or restrict coolant return flow.

COOLANT IN fitting Output from unit under test.

5. COMPRESSOR AIR RETURN

PRESSURE meter (M1) Indicates discharge pressure from compressor under test.

FLOW meter (M2) Indicates discharge flow from compressor under test.

Valve (V1) Used to control or restrict discharge of compressor under test.

AIR IN fitting Output from unit under test.

Figure 4-1. Left Control Panel (Sheet 2)

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6. CONTROL VALVE

Switch S2 Selects driving signals to open or close either type control valve.Normally set to OFF.

400 Hz indicators (DS3, DS4) OPEN or CLOSE flickers to indicate driving signals when 400 Hzcontrol valve is operated.

DC indicators (DS5 - DS8) All four flicker in sequence to indicate driving signals when dccontrol valve is operated.

S3 must be set correctly before S2 is operated to prevent damage to control valve motor.

Switch S3 Selects type of control valve to be tested - dc or 400 HZ.

Connector J2 Connects control valve to be tested.

7. AC POWER outlet (J3) 120 Vac 60 Hz available when CB1 is on.

8. 60 Hz POWER

Indicators (DS9-DS11) Indicate presence of each phase.

Circuit breaker CB1 Controls all 60 Hz power to left side of test bench.

9. 400 Hz POWER

FREQUENCY meter (M8) Displays frequency of selected phase.

VOLTAGE meter (M9) Displays RMS voltage of selected phase.

VOLTAGE CONTROL (T1) Adjusts voltage across load from zero to 120.

AMPERAGE meter (M10) Displays current through load of selected phase.

PHASE MONITOR switch (S4) Selects phase for display of frequency, voltage and current.BYPASS settings bypass the displays and provides isolationbetween phases during switching.

Indicators (DS12 - DS14) Indicate presence of each phase at input of voltage control.

Circuit breaker CB2 ConnectorJ1

Controls all 400 Hz power to test bench. Supplies power to thechiller, refrigerant compressor, or coolant pump under test.

Figure 4-1. Left Control Panel (Sheet 3)

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4-6

Figure 4-2. Control Valve Driving Signals

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4-7

Figure 4-3. Right Control Panel (Sheet 1 of 3)

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4-8


1. REFRIGERANT PRESSUREgauge

Displays pressure in refrigerant measuring tube.

2. Scale Provides reference for adjusting the sight-gauge light beams.

3. Sight-gauge Displays level of refrigerant in refrigerant measuring tube.

4. Upper sight-gauge lightbeam assembly (PEC-1)

Causes solenoid valves SOL-F/V11 and SOL-E/V13 to close byde-energizing relay CR-F when measuring tube is filled.

5. Ground stud and cable Provides grounding for equipment under test.

6. Lower sight-gauge lightbeam assembly (PEC-3)

Causes solenoid valve SOL-C/V10 to close by de-energizing relay CR-Cwhen measured volume of refrigerant has been transferred from testbench.

7. PURGE VALVE (V5) Provides for release of refrigerant from chiller unit and from test bench.

8. REFRIGERANT VACUUMmanometer gauge

Displays vacuum in millimeters of mercury (Hg), absolute pressure.

9. EVACUATION/REFRIGERANT CHARGEfitting

Connects to chiller unit for evacuation or charging.

10. GAS BALLAST valve (V17) Provides for ballasting the vacuum pump exhaust chamber with smallamount of air to eliminate condensation.

11. 60 Hz POWER CB4 circuitbreaker

Controls 120 Vac, 60 Hz power to right side of test bench - independentof CB1 on left side.

12. PANEL POWER switch withindicator (TGS-2/NLT-2)

Switch controls 120 Vac, 60 Hz power to all controls on service stationpanel except VACUUM PUMP switch. Indicator comes on with power.

13. 5 AMP fuse with indicator(FU-5/NLT-5)

Provides protection of low-current circuits controlled by service stationpanel (not of motor or heater circuits). Indicator comes on if fuse fails.

14. VACUUM PUMP switchwith indicator(TGS-1/NLT-1)

Switch controls 120 Vac, 60 Hz power to pump motor and vacuum breaksolenoid valve. When motor is turned off, vacuum break valve opens torelieve vacuum in pump. Indicator comes on with pump.

15. Vacuum gauge (M-4) Displays vacuum at lower pressures - down to about 20 microns Hg,abs.; one micron equals 0.001 millimeter.

16. MEASURING TUBEHEATER switch withindicator (TGS-4/NLT-4)

Switch controls power to heater control circuits. Indicator goes out whenrefrigerant is ready for charging, indicating charging circuits are enabled.

17. CYLINDER HEATERswitch with indicator(TGS-3/NLT-3)

Switch controls power to heater control circuits. Indicator and heatercycle OFF and ON as refrigerant temperature is maintained.

Figure 4-3. Right Control Panel (Sheet 2)

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4-9


18. REFRIGERANTMEASURING TUBE switchwith indicators RSS-1/NLT-6,NLT-7):

Switch is spring-loaded to OFF and requires only momentary actuation.Indicators F and C come on during respective operation.

FILL position FILL causes solenoid valves SOL-F/V11 and SOL-E/V13 to open, fillingmeasuring tube.

CHARGE position When refrigerant in measuring tube is ready, CHARGE causes solenoidvalve SOL-C/V10 to open, transferring refrigerant from measuring tubeto chiller unit.

19. Function selector switch withindicators (RSS-2/NLT-8,NLT-11):

Indicator comes on for each switch position.

PUMP TEST position Solenoid valve SOL-V/V8 opens to connect vacuum pump suction tomanometer and vacuum gauge.

EVACUATE position Solenoid valves SOL-V/V8 and SOL-P/V9 open to connect vacuumpump suction to gauges and to chiller unit.

PRESSURE TEST position Solenoid valve SOL-P/V9 opens, and SOL-V/V8 closes, so vacuum inchiller can be monitored after evacuation. Test bench can also be testedfor leaks if chiller unit is not connected.

CHARGE position When refrigerant in measuring tube is ready, CHARGE causes solenoidvalve SOL-C/V10 to open, transferring refrigerant from measuring tubeto chiller unit.

Figure 4-3. Right Control Panel (Sheet 3)

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4-10

Table 4-1. Preoperational Checkout - Left Panel

Procedure Observation

NOTE

Shop ambient temperature is required to be between 60 and 80 °F.

1. Set switches S1 and S2 and circuit breakers CB1 and CB2to OFF.

2. Verify that coolant tank is filled two to four inches from itstop with distilled water. If tank was previously drained andleft empty, be sure drain valve on tank is closed.

Water should be clear and free ofcontamination.

NOTE

Allow test equipment to warm up for 10 minutes prior to testing.

3. Turn on 60 Hz POWER CB1. Three 60 Hz POWER indicators come on.Verify all 10 digital panel meters illuminate;type of illumination is not significant.

4. Set PHASE MONITOR switch to BYPASS.

5. [1] [1X] Set master power circuit breaker to motorgenerator to ON.

6. [1] [1X] Prior to power up of the motor generator, setvariable power transformer to HIGH position.

7. [1] [1X] Set start switch on motor generator control box toSTART.

8. Turn on 400 Hz POWER CB2. Three 400 Hz POWER indicators come on.VOLTAGE, FREQUENCY, and AMPERAGEmeters indicate approximately zero.

NOTE

[1] [1X] If frequency is out of tolerance, adjust variable transformer for correct frequency.Transformer is located by 400 Hz generator.

9. Set PHASE MONITOR switch to A and rotate VOLTAGECONTROL.

VOLTAGE meter indicates voltage is adjustablethrough range of 0 to more than 120 VOLTSAC, FREQUENCY meter indicates 400 (±10)Hz, and AMPERAGE meter indicatesapproximately zero.

10. Repeat step 9 with PHASE MONITOR switch set to B andto C.

11. Set PHASE MONITOR switch to A.

12. Set VOLTAGE CONTROL to 0.

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4-11

Table 4-1. Preoperational Checkout - Left Panel - Continued


13. Set PHASE MONITOR switch to BYPASS.

14. Set 400 Hz POWER CB2 to OFF.

15. [1] [1X] Set start-stop switch on 400 Hz motor generatorcontrol panel to STOP.

16. Observe meters for COOLANT SUPPLY, COOLANTRETURN, and COMPRESSOR AIR RETURN.

Flowmeters indicate approximately zero,temperature indications depend on ambienttemperature, and pressure indications are notsignificant.

When closing manual shutoff valves, use of excessive force can damage valve seats.

17. Check the following valves for free operation and closethem by turning fully clockwise:

AIR PURGE

COOLANT SUPPLY

COOLANT RETURN

COMPRESSOR AIR RETURN

18. Set COOLANT PUMP switch to ON. Two COOLANT PUMP indicators come on andcoolant pump can be heard or felt to be running

19. On COOLANT HEATER CONTROL panel, set toggleswitch to ON.

Indicator on COOLANT HEATER CONTROLpanel may come on depending on temperatureof water in tank and setting of thermostatcontrol on panel. If necessary, increase thermo-stat setting to check out indicator.

20. Turn off COOLANT PUMP and COOLANT HEATERCONTROL switches.

21. Set CONTROL VALVE selector switch S3 to DC; setCONTROL VALVE OPEN-OFF-CLOSE switch S2 toOPEN and to CLOSE.

Four dc indicators go on and off in correctsequence to indicate selected operation.

NOTE

If OPEN and CLOSE indicators do not come on, remove left-rear panel and verify that circuit breakerCB3 (Figure 5-1, 24) is pushed in.

22. Set 60 Hz POWER CB1 to OFF.

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4-12

Table 4-2. Preoperational Checkout - Right Panel


• Do not leave MEASURING TUBE HEATER switch on when measuring tube is empty. Equipmentdamage will occur.

• When closing manual shutoff valves, use of excessive force can damage valve seats.

1. Set right-hand panel controls as follows:

60 HZ POWER CB4 - ON Indicator on

PANEL POWER switch - ON Indicator on

CYLINDER HEATER switch - ON Indicator on

MEASURING TUBE HEATER switch - ON Indicator on

MEASURING TUBE HEATER switch - OFF Indicator off

VACUUM PUMP switch - OFF Indicator off

PURGE valve - closed

GAS BALLAST valve - closed

2. Remove right-rear panels.

3. Open LIQUID valve on freon cylinder two turns from fullyclosed.

4. Open valves V6 (Figure 5-1, 82) and V7 (78) 1-1/2 turnsfrom fully closed.

REFRIGERANT PRESSURE gauge on cylinderindicates pressure (pressure varies withtemperature). Liquid eye displays liquid in line.

5. Check sight glass on vacuum pump. Oil level must be 1/4 inch minimum above bottomof sight glass.

6. Set function selector switch to PUMP TEST. PUMP TEST indicator comes on.

7. Turn on VACUUM PUMP switch. VACUUM PUMP indicator comes on and vacuumpump starts. REFRIGERANT VACUUMmanometer and vacuum meter indicate avacuum pressure.

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4-13

Table 4-2. Preoperational Checkout - Right Panel - Continued


NOTE

Gas ballast should be open to prevent moisture condensation inside pump. However, if 100 microns orless cannot be attained, slowly close GAS BALLAST valve until knocking can be heard in vacuumpump. Open GAS BALLAST valve until knocking is not heard.

8. Open GAS BALLAST valve about two turns. VACUUM gauge should indicate 100 microns orless within 5 minutes.

9. Turn off VACUUM PUMP switch.

10. Close GAS BALLAST valve.

11. Set function selector switch to EVACUATE. EVACUATE indicator comes on.

12. Set function selector switch to PRESSURE TEST. PRESSURE TEST indicator comes on.

13. Set function selector switch to CHARGE. CHARGE indicator comes on.

14. Set CYLINDER HEATER switch to OFF.

15. Set PANEL POWER switch to OFF.

16. Set 60 Hz POWER CB4 to OFF. VACUUM gauge pointer settles on center of threedots at right. Manometer indicates about 120 mm.

17. Close LIQUID valve on freon cylinder.

18. Replace rear panels.

19. Check valve V13. Valve V13 should be fully closed. Opening ofV13 during charging will allow refrigerant vaporto be vented to the atmosphere.

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4-14

CHAPTER 5MAINTENANCE INSTRUCTIONS

5.1 SCOPE.

This chapter contains procedures to checkout, troubleshoot, and repair the test bench. Ordinary hand tools and the equipmentlisted in Table 2-1 are required. Table 5-1 through Table 5-5 include checkout of the functional test bench subsystems. If acheckout step fails, refer to a related troubleshooting step in one of Table 5-6 through Table 5-10. Troubleshooting tables arealso arranged by functional subsystems, and the steps suggest faulty or out-of-adjustment part that would cause the failure.After making an adjustment, repeat the checkout step that failed. After a repair, repeat the procedure.

5.1.1 Component Location. Refer to Figure 4-1 and Figure 4-3 for location and function of front panel components. Forlocation of components within the test bench, refer to Figure 5-1.

5.2 REPAIR.

The Remedy column in the troubleshooting tables usually includes the procedures to make the repair, since there are norequirements beyond common shop practice.

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5-1

Figure 5-1. Test Repair Set Component Locations (Sheet 1 of 5)

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5-2

Figure 5-1. Test Repair Set Component Locations (Sheet 2)

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5-3

Number Component

1. V16, air pressure regulator

2. FL1, 208 Vac 3-phase 60 Hz filter

3. FL2, 208 Vac 3-phase 400 Hz filter

4. M8, 400 Hz POWER-FREQUENCY meter

5. A1, COOLANT HEATER CONTROL panel

6. M9, 400 Hz POWER-VOLTAGE meter

7. T1, 400 Hz POWER-VOLTAGE CONTROL transformer

8. TB1, terminal strip - 60 Hz neutral

9. M10, 400 Hz POWER-AMPERAGE meter

10. TB2, terminal strip - 60 Hz phase C

11. V4, air purge shutoff valve

12. MT3, coolant supply pressure sensor

13. RT3, coolant supply temperature sensor

14. Air purge return assembly

15. S4, 400 HZ POWER - PHASE MONITOR switch

16. J4 through J14, test jacks for PS1, PS2, and electronic enclosure circuits

17. Wire loop, test point for testing 400 Hz current with clamp on ammeter

18. CB2, 400 Hz POWER circuit breaker

19. T2, 400 Hz current transducer

20. Electronic enclosure

21. CB1, 60 Hz POWER circuit breaker

22. PS2, dc power supply

23. PS1, dc power supply

24. CB3, circuit breaker at input of PS1 and PS2

25. Coolant tank

26. RT1, coolant temperature sensor

27. Coolant tank drain valve

28. HR1, coolant heater assembly

29. Coolant pump and motor assembly

30. Coolant filter


T.O. 33D9-17-89-1

5-4

Number Component

31. MT5, coolant return flow transducer

32. V18, compressor air return relief valve - 250 psi

33. Oil separator, compressor air return

34. A3, range extending amplifier

35. RT2, coolant return temperature sensor

36. MT2, coolant return pressure sensor

37. A2, linearizer

38. V1, compressor air return flow transducer

39. MT4, compressor air return transducer

40. MT1, compressor air return pressure sensor

41. V2, coolant return shutoff valve

42. V3, coolant supply shutoff valve

43. M2, COMPRESSOR AIR RETURN FLOW meter

44. M5, COOLANT RETURN FLOW meter

45. S1, COOLANT PUMP switch

46. M1, COMPRESSOR AIR RETURN PRESSURE meter

47. M4, COOLANT RETURN PRESSURE meter

48. M7, COOLANT SUPPLY PRESSURE meter

49. M3, COOLANT RETURN TEMPERATURE meter

50. M6, COOLANT SUPPLY TEMPERATURE meter

51. V14, refrigerant pressure relief valve - 235 psi

52. V13, shutoff valve

53. REFRIGERANT PRESSURE gauge

54. PS-2, pressure switch

55. PEC-3 (J101), photoelectric controller-charge (J103 top front)

56. PEC-1 (J102), photoelectric controller-fill (J104 top front)

57. M4, vacuum meter-adjustment screw on top

58. PC2BA, program control center

59. CR-H, tube heater relay

60. CR-C, charge relay

61. CR-F, fill relay


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5-5

Number Component

62. V17, GAS BALLAST valve

63. SOL-P/V9, evacuate and pressure test solenoid valve

64. PT-4, vacuum transducer

65. SOL-V/V8, vacuum solenoid valve

66. Suction line from vacuum pump

67. Cap-test stand transducer connection

68. Suction line to oil dropout tank and vacuum breaker solenoid valve, SOL-B

69. Oil mist, eliminator

70. Vacuum pump

71. Oil level sight glass

72. Drive belt pulley guard

73. Oil drain valves

74. PS-1, refrigerant cylinder pressure switch

75. TS-1, refrigerant cylinder temperature switch

76. Refrigerant cylinder

77. Hose from refrigerant cylinder


79. SOL-F/V11, fill solenoid valve

80. V15, check valve

81. SOL-C/V10, charge solenoid valve


83. Measuring tube heater base plate

84. EVACUATE/REFRIGERANT CHARGE fittings

85. V5, PURGE VALVE

86. VACUUM manometer gauge

87. SOL-E/V12, measuring tube vent solenoid valve

88. Measuring tube assembly


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5-6

Table 5-1. Power Checkout

Step Operation Normal IndicationTrouble Ref.(Table 5-6)

1. Set 60 Hz POWER CB1 ON. 60 Hz POWER indicators come on. 1.

2. Set START-STOP switch on 400 Hzgenerator control box to START.

3. Set 400 Hz POWER CB2 ON. 400 Hz POWER indicators come on. 1.

4. Set PHASE MONITOR switch to Aand set VOLTAGE CONTROL toacquire 120-volt indication on 400 HzPOWER VOLTAGE meter.

400 Hz POWER VOLTAGE meter M9 indicates120 (±2.5) volts.

3.

5. Set 400 Hz POWER CB2 OFF.

NOTE

Allow 10-minute warm-up for digital meters in test bench.

6. Set PHASE MONITOR switch toBYPASS.

7. Connect cable 25-79312-2 to 400 HzPOWER J1.

NOTE

Ensure that connector adapter is clocked to keyway position 2.

8. Connect connector adapterBACC45HR12-01P to cable end.

9. Connect phase meter to connectoradapter pins 1, 2, 3 (phase A, B, C,respectively).

10. Set 400 Hz POWER CB2 ON. Indicated phase sequence is A-B-C. Miswiringduringrepair.Reverse anytwo of phasewires atinput side ofFL2.

11. Set 400 Hz POWER CB2 OFF anddisconnect phase meter fromconnector adapter.

12. Set PHASE MONITOR switch toPHASE A and connect multimeter toconnector adapter pin 1 and to groundstud (Figure 4-3, 5).

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5-7

Table 5-1. Power Checkout - Continued


13. (Deleted)

14. Set 400 Hz POWER CB2 ON andvary VOLTAGE CONTROL knob.

Voltage varies smoothly from about zero to at least120 Vac.

2.

NOTE

If using a multimeter capable of reading frequency, steps 19 and 20, may beperformed in conjunction with the performance of steps 15 and 16. If completed thisway, disregard performing steps 17 and 18, and proceed to step 21 after correct indi-cations are obtained for both voltage and frequency readings.

15. Set VOLTAGE CONTROL to acquire120 volt indication on multimeter.

400 Hz POWER VOLTAGE meter M9 indicates120 (±2.5) volts.

3.

16. Repeat steps 14 and 15 for phases Band C at connector adapter pins 2 and3, respectively.

3.

17. Set 400 Hz POWER CB2 OFF anddisconnect multimeter from connectoradapter.

18. Set PHASE MONITOR switch toPHASE A and connect frequencycounter to connector adapter pin 1 andto ground cable.

19. Set 400 Hz POWER CB2 ON and SetVOLTAGE CONTROL knob to 120Vac.

Indications on frequency counter and 400 HzPOWER FREQUENCY meter M8 are within 3 Hz.

3.

20. Repeat steps 18 and 19 for phases Band C at connector adapter pins 2 and3, respectively.

21. Set VOLTAGE CONTROL fullycounterclockwise.

22. Set 400 Hz POWER CB2 OFF anddisconnect frequency counter,connector adapter.

23. Connect chiller unit for load at end ofcable 25-79312-2. Connect groundcable (Figure 4-3, 5) to chiller unit.

24. Connect clamp-on ammeter onto wireloop (Figure 5-1, 17) in rear of testbench.

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5-8 Change 1



25. Turn on 400 Hz POWER CB2 andslowly adjust VOLTAGE CONTROLto acquire 120 (±2.0) volt indicationon 400 Hz POWER VOLTAGE meter.

26. Measure all three phases by selectingwith PHASE MONITOR switch.

Indications on clamp-on meter and 400 HzAMPERAGE meter are within 0.5 amp.

3.

27. Set 400 Hz POWER CB2 OFF.Disconnect and store chiller unit andcable.

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Change 1 5-8.1/(5-8.2 blank)



28. Set VOLTAGE CONTROL fullycounterclockwise.

29. Set START-STOP switch on 400 Hzgenerator control box to STOP.

30. Turn off CB1, unless othermaintenance is being performed.

31. In rear of test bench, ensure CB3 (24)is on.

32. Using multimeter, measure dc voltageat test point J4 (16) with reference(- lead) to J14.

+5.3 (±0.02) Vdc. 4.

33. Measure dc voltage at test point J5with reference to J14.

+15.0 (±0.1) Vdc. 4.


-15.0 (±0.1) Vdc. 4.


+12.0 (±0.1) Vdc. 4.

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5-9

Table 5-2. Control Valve Driver Circuit Checkout

Step Operation Normal Indication

TroubleReference(Table 5-7)

CONTROL VALVE switch S3 shall be set correctly before connecting control valve and operatingOPEN/CLOSE switch S2. Failure to comply could result in damage to valve and test bench.

NOTE

If directed to this procedure as a result of maintenance, perform power checkout, Table 5-1, beforeproceeding.

1. Set 60 Hz POWER CB1 to ON.

NOTE

• Allow test equipment to warm up for 10 minutes prior to testing.

• Perform steps 2 through 10 if dc type control valve is available.

2. Hook up control valve assembly perT.O. 35E9-35-22.

3. Set CONTROL VALVE switch S3 toDC.

4. Set OPEN-OFF-CLOSE switch S2 toCLOSE.

Control valve stop pin moves toward the closedposition until fully closed.

5. Set OPEN-OFF-CLOSE switch S2 toOFF.

6. Connect oscilloscope channel 1 to J9and channel 2 to J8 (Figure 5-1, 16).Connect oscilloscope signal ground toJ14.

7. Connect dc control valveVAK-36/F37U-22 to J2 using cable25-79312-4.

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5-10

Table 5-2. Control Valve Driver Circuit Checkout - Continued


TroubleReference(Table 5-7)

8. Set OPEN-OFF-CLOSE switch S2 toOPEN.

CONTROL VALVE dc indicators cycle in OPENsequence. Valve opens. Oscilloscope display asshown below. Disregard distortion, overshoot, andspikes in display.

1, 2, 3.

9. Set OPEN/CLOSE switch S2 toCLOSE.

CONTROL VALVE dc indicators cycle in CLOSEsequence. Valve closes. Oscilloscope display asshown below.

1, 2, 3.

10. Set OPEN/CLOSE switch S2 to OFF,and disconnect dc control valve andoscilloscope.

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5-11

Table 5-3. Coolant System Checkout

Step Operation Normal IndicationTrouble Ref(Table 5-8)

NOTE

Prior to making any hose connections with hose assemblies, inspect quick-disconnect fittingsand hoses for ease of operation and visible defects, including debris.

1. Connect test stand to test benchwith two 25-79314-1 hoses; teststand COOLANT IN toCOOLANT OUT and test standCOOLANT OUT to COOLANTIN.

2. Plug test stand power cable intoac POWER receptacle (Figure4-1, 7) on test bench, and settest stand power switch to on.

3. Close COOLANT RETURNvalve by turning fully clockwise.

4. Set COOLANT HEATERCONTROL switch OFF, turnCB1 ON, and set COOLANTPUMP switch S1 ON.

COOLANT PUMP indicators come on. 1.

NOTE

Allow test equipment to warm up for 10 minutes prior to testing.

5. Open COOLANT SUPPLYvalve about one turn.

T.O. 33D9-17-89-1

5-12 Change 3

Table 5-3. Coolant System Checkout - Continued


Flow meters are normally not damaged by reasonable excess in fluid velocity or hydraulic shock,provided it is full of fluid. Excessive overspeed of a dry transducer may cause damage to testbench flow meter.

NOTE

• Momentary fluctuation of indicator meter is normal, provided above caution is observed.

• On test stand coolant flow rotameter gauge, read scale opposite bottom of flare on movingindicator.

6. Very slowly turn COOLANTRETURN valve counterclock-wise to attain flow rate of about1 pound per minute. Wait 1minute to be sure all air isforced from coolant lines.

COOLANT RETURN FLOW indicationincreases to 1 pound per minute and pump canbe heard running.

1.

7. Open COOLANT SUPPLYvalve.

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Change 3 5-12.1/(5-12.2 blank)



8. Adjust COOLANT RETURNvalve for a minimum of 5pounds per minute flow and aminimum of 14 (±3) psig onCOOLANT SUPPLYPRESSURE meter on test bench.

A minimum of 5 pounds per minute flow and aminimum of 14 (±3) psig indicated on test standmeters.

2.

NOTE

If MR1000 type flow meter is installed in test bench, meter will display reading to the thou-sandths place (three decimal places). Reading shall be rounded to the hundredths place (twodecimal places).

9. Adjust test bench valves for teststand indications of 1.0 (±0.2),3.0 (±0.2), and 5.0 (±0.2)pounds per minute coolant flow.

Test bench COOLANT RETURN FLOW meterindicates within 0.45 pound per minute of eachtest stand indication.

5.

NOTE

COOLANT RETURN valve may require slight opening to attain required pressure, but do notexceed 0.5 pound per minute on test stand flow gauge.

10. Close COOLANT RETURNvalve and adjust COOLANTSUPPLY valve for test standpressure indications of 5 (±0.5),10 (±0.5), and 15 (±0.5) psig.

Test bench COOLANT SUPPLY PRESSUREmeter M7 indicates within 0.5 psig of each teststand indication.

4.

Test bench COOLANT RETURN PRESSUREmeter M4 indicates within 0.5 psig of each teststand indication.

3.

11. Adjust test bench coolant controlvalves for four to 5 pounds perminute flow at not less than 10psig as indicated by test stand.After two-minute wait forstabilization, read test standtemperature.

COOLANT SUPPLY TEMPERATURE meterM6 indicates within 0.4 °F of test stand tempera-ture.

7.

COOLANT RETURN TEMPERATURE meterM3 indicates within 0.4 °F of test stand tempera-ture.

6.

T.O. 33D9-17-89-1

5-13



11. - ContNOTE

Prior to next step, COOLANT SUPPLY TEMPERATURE must indicate less than 80 °F. Ifnecessary, turn off COOLANT PUMP switch S1. Drain and refill coolant tank with cooldistilled water to within two to four inches from top. Turn on S1.

12. Adjust flow for 2 to 3 poundsper minute at not less than 10psig as indicated on test stand.Note that COOLANT SUPPLYTEMPERATURE indicates lessthan 80 °F. Record thetemperature.

13. Turn on COOLANT HEATERCONTROL switch and adjustdial to a setting 10 °F abovetemperature recorded in step 12.

COOLANT SUPPLY TEMPERATURE indicatesthe dial setting (±3) degrees within 25 minutes.

8.

14. After 25 minutes, turn offCOOLANT HEATERCONTROL and COOLANTPUMP switches.

15. Close COOLANT SUPPLY andCOOLANT RETURN valves.

16. Close AIR PURGE valve fullyclockwise.

17. Verify facility air is connected totest bench.

18. Disconnect hose 25-79314-1from test bench COOLANTSUPPLY and connect it to AIRPURGE SUPPLY.

19. Disconnect other hose25-79314-1 from test benchCOOLANT RETURN andconnect it to PURGE RETURN.

20. Slowly open AIR PURGE valveto purge coolant from test stand.With valve fully open, purge for5 minutes or until test standrotameter appears dry.

Air bubbles in test stand flow gauge indicatecoolant has been returned to test bench tank.

21. Disconnect and store hoseassemblies.

T.O. 33D9-17-89-1

5-14

Table 5-4. Air Regulation Checkout


TroubleRef (Table

5-9)

1. Verify facility air is connected to test bench.

2. Set 60 Hz POWER CB1 on.

NOTE

• Allow test equipment to warm up for 10 minutes prior to testing.

• Prior to making any hose connections with hose assemblies, inspect quick-disconnect fittings andhoses for ease of operation and visible defects, including debris.

3. Connect hose assembly 25-79314-1 from AIR PURGESUPPLY to test stand COOLANT IN.

4. Connect hose assembly 25-79314-1 to test standCOOLANT OUT, and leave other end disconnected.

5. Slowly open AIR PURGE valve. Test stand COOLANT PRES-SURE gauge indicates 20 (±2)psig.

1.

6. Close AIR PURGE valve.

7. Connect free end of hose assembly 25-79314-1 to testbench PURGE RETURN to relieve pressure.

8. Remove and store hoses.

9. Verify the following valves are closed: COMPRESSORAIR RETURN, nitrogen cylinder LIQUID, nitrogenregulator.

10. Connect nitrogen regulator through nitrogen adapterassembly (Figure 2-1) and hose assembly 25-79840-1 totest stand AIR IN.

11. Connect hose assembly 25-79314-2 to test stand AIROUT and to test bench COMPRESSOR AIR RETURNAIR IN.

T.O. 33D9-17-89-1

Change 3 5-15

Table 5-4. Air Regulation Checkout - Continued


TroubleRef (Table

5-9)

COMPRESSOR AIR RETURN FLOW meter shall not be allowed to exceed 2.5 CFM. Failure tocomply could result in damage to flow transducer MT4.

NOTE

• Test stand or test bench should not exceed 225 psig. Pressure relief valve may open.

• When reading airflow rotameter on test stand, scale opposite center of ball in indicator should beused.

12. Verify test stand PRESSURE gauge indicates 0.0 (±2.0)psig. Slowly open nitrogen valve and adjust regulator fortest stand PRESSURE gauge indications of 50 (±3) and100 (±4) psig. COMPRESSOR AIR RETURN valve maybe opened slightly for fine adjustment.

COMPRESSOR AIR PRESSUREmeter M1 indicates within 5 psigof test stand at each pressuresetting.

2.

13. Close nitrogen cylinder valve and bleed pressure fromCOMPRESSOR AIR RETURN VALVE.

14. Connect nitrogen source through a hose to a tee fittingand then to test stand COOLANT IN.

15. Connect open end of tee (step 14) through a shut off valveto the test stand AIR IN. Close the shut off valve.

16. On test bench, fully open COMPRESSOR AIR RETURNvalve.

17. Adjust nitrogen source pressure to 10 to 15 psig indicationon test stand COOLANT pressure gauge. NOTE: It maybe necessary in the following step to maintain 10 to 15psig on test stand COOLANT pressure gauge in steps 18and 20.

18. Slowly open valve (step 15) for 0.5 (±0.2) ACFM indica-tion on test bench COMPRESSOR AIR RETURN FLOWmeter.

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TroubleRef (Table

5-9)

19. (Deleted)

20. Slowly open valve (step 15) for 1.5 (±0.2) ACFM indica-tion on test bench COMPRESSOR AIR RETURN FLOWmeter.

21. Record the following readings:

Test STAND Airflow

Test BENCH compressor air return flow

Test STAND coolant pressure

22. Reduce nitrogen source pressure to 0 psig.

23. Compute readings taken in step 21 as follows:

T.O. 33D9-17-89-1

Change 1 5-17



TroubleRef (Table

5-9)

24. Compute sea level flow rate for the test STAND and testBENCH flow meters as follows:

25. Test Bench (Sea level) and Test Stand (Sea level) shallagree within (± 0.2).

Within tolerance 2.

26. Close COMPRESSOR AIR RETURN valve.

27. Disconnect all hoses connection nitrogen source; testbench and test stand.

28. Turn off nitrogen regulator, close nitrogen valve and closeCOMPRESSOR AIR RETURN VALVE.

29. Disconnect all hoses. Remove tee from hose assembly25-79314-1 and reinstall nipple removed in step 14. Storehose assemblies and tee.

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Table 5-5. Refrigeration Controls Checkout

Step Operation Normal IndicationTrouble Reference

(Table 5-10)

• 120-Vac power is present inside cabinet when power cables are connected. Serious shock hazardexists when panels are off. Failure to comply may result in personnel injury.

• Do not exceed 235-psig pressure during the following tests. Relief valve may open. Failure tocomply may result in personnel injury.

NOTE

Schematics FO-2 and FO-3 illustrate plumbing and electrical refrigerant controls by nomenclature,function, and number. These identifying numbers are nonstandard but agree with engineering datasupplied to depot and are useful here for checkout and troubleshooting.

1. Verify CB4 is set to OFF. Disconnectrefrigerant cylinder heater cable P108(Figure 5-1, 58) from J108 in rear of testbench.

2. Connect multimeter across cableconnector P108 pins X and Y. (Pin Y iscrossways, and pin X is next to Yclockwise when viewing P108 pins.)

Multimeter indicates less than one ohmresistance.

1.

3. Ensure that both refrigerant cylindervalves are closed.

4. Remove cap (Figure 2-1, 3) from nitrogenadapter assembly, and connect assemblyto nitrogen regulator.

Pressure is present in the hose. Faceshield and leather gloves must be used to prevent personnel injury.

5. Close valve V7 and close the in-lineshutoff valve on the end of supply tankhose (Figure 5-1, 77).

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5-19

Table 5-5. Refrigeration Controls Checkout - Continued


(Table 5-10)

NOTE

If using self-sealing hoses, perform step 6, then proceed to step 8. If not using self-sealing hoses,proceed to step 7.

6. Disconnect hose (Figure 5-1, 77) fromin-line shutoff valve. Connect hose toreclaimer and reclaim per manufacturer’sinstructions.

7. Disconnect the in-line shutoff valve fromV7. Connect reclaimer system to in-lineshutoff valve with another refrigerationhose. Open in-line shutoff valve andreclaim in accordance with reclaimermanufacturer’s instructions. Removein-line shutoff valve and hose fromreclaimer.

8. Connect reclaimer system toEVACUATION/CHARGE port on thefront of the test bench. Set 60 Hz powerCB4 to ON.

60 HZ POWER indicator on. Table 5-6, step 1.

9. Turn TGS-2 (PANEL POWER SWITCH)to ON.

PANEL POWER indicator NLT-2 on. 4, 5.

10. Set RSS-1 (REFRIGERANTMEASURING TUBE SWITCH) selectorswitch to FILL.

RSS-1 FILL indicator on.

11. Reclaim from test bench plumbing andfill tube in accordance with reclaimermanufacturer’s instructions.

12. Set TGS-2 (PANEL POWER SWITCH)to OFF.

All indicator lights off. Switch RSS-1repositions to OFF.

13. Connect hose (77) to uncapped fitting onnitrogen adapter assembly (Figure 2-1, 3).

14. Connect hose assembly, Part No.25-79840-1, from test stand AIR IN tonitrogen adapter assembly.

15. Connect hose assembly, Part No.25-79840-2, to test stand AIR OUT, andleave quick-disconnect end free.

16. Apply nitrogen and vary pressure byreleasing pressure at nitrogen source;monitor both multimeter and test standAIR PRESSURE gauges.

Resistance increases to greater than 1megohm with pressure increase to 126 to150 psig and returns to less than one ohmwhen pressure falls below 126 psig.

2.

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5-20



(Table 5-10)

17. Adjust PS-1, if required, and retest ifadjusted.

18. Disconnect multimeter and turn offnitrogen source. Reconnect connectorP108.

19. Disconnect hose (Figure 5-1, 77) slowlyto bleed pressure from nitrogen adapterassembly; replace cap (Figure 2-1, 3), andreconnect hose to valve V7. Open in-lineshutoff valve fully and valve V7 1-1/2turns from fully closed position.

20. Disconnect P105 from J105 located onprogram control center (Figure 5-1, 58) inrear of test bench, and connect shortingplug assembly, Part No. P-304-AB (Table2-1), into J105.

21. Connect reclaimer system toEVACUATE/REFRIGERANT CHARGEoutlet on front of test bench. Preparereclaimer to accept freon as permanufacturer’s instructions.

22. Set PANEL POWER switch TGS-2 toON.

PANEL POWER indicator NLT-2 on. 4, 5.

23. Loosen thumbscrews on lower sight-gauge light beam assembly (Figure 4-3,6) and insert a piece of black paperbetween sight-gauge and rounded half oflight beam assembly.

24. Set selector switch RSS-2 (Figure 4-3,19) to CHARGE.

CHARGE indicator NLT-11 on. 4.

25. Turn on MEASURING TUBE HEATERswitch TGS-4.

MEASURING TUBE HEATER indicatorNLT-4 may flash on momentarily whenTGS-4 is turned on.

26. Momentarily set REFRIGERANTMEASURING TUBE switch RSS-1 toCHARGE, and then turn offMEASURING TUBE HEATER switchTGS-4.

REFRIGERANT MEASURING TUBE Cindicator NLT-6 comes on and stays on.

4, 14.

27. Reclaim in accordance with reclaimermanufacturer’s instructions, ensure refrig-erant pressure gauge on test bench hasregistered zero. Remove reclaimer hosefrom EVACUATE/REFRIGERANTCHARGE outlet.

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5-21



(Table 5-10)

NOTE

Pins are numbered as follows when viewing P105 contacts:

28. Connect multimeter across P105 pins 1and 2.

Multimeter indicates greater than 1megohm resistance.

3.

29. Resistance decreases to less than one ohmwhen pressure increases to 145 to 160psig, and returns to greater than 1megohm when pressure decreases to 145psig minimum.

30. Apply nitrogen and vary pressure to testoperation of pressure switch. Observeboth test stand pressure gauge andmultimeter.

Resistance decreases to less than one ohmwhen pressure increases to 100 to 122psig, and returns to greater than 1megohm when pressure decreases to 100psig minimum.

3.

31. Adjust nitrogen pressure for test standindication of 125 psig.

Test bench REFRIGERANT PRESSUREgauge PI-2 indicates 125 (±5) psig.

9.

32. Turn off nitrogen source and relievepressure by opening purge V5 on testbench. Disconnect test stand.

33. Turn off PANEL POWER switch TGS-2and remove shorting plug, Part No.P-304-AB, and reconnect P105 into J105.Remove black paper from between lowersight-gauge light beam assembly.

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5-22 Change 1



(Table 5-10)

34. Set refrigerant controls on test bench asfollows:

NOTE

Zero (center dot) both micron gauges on test stand and test bench before proceeding to step 34a.

a. PANEL POWER switch TGS-2... on

b. PURGE VALVE V5... close

c. GAS BALLAST VALVE... close

Use two wrenches when loosening or tightening fittings to avoid stressing plumbing system. Failure tocomply may cause equipment damage.

35. Remove cap (Figure 5-1, 67) from fittingbetween solenoid valves V8 (65) and V9(63).

36. Connect test stand vacuum gauge trans-ducer to fitting, connect test stand elec-trical power connector, turn on test standswitch, and allow a 10-minute warm-upperiod.

37. Set VACUUM PUMP switch TGS-1 toON.

VACUUM PUMP indicator NLT-1 on,pump operates.

4, 6.

38. Set selector switch RSS-2 to PUMPTEST.

PUMP TEST indicator NLT-8 on. 4.

REFRIGERANT VACUUM manometerindicates a vacuum.

7.

NOTE

• If 100 microns or less cannot be attained, slowly close GAS BALLAST valve and then slightlyopen GAS BALLAST valve.

• GAS BALLAST valve should be open to prevent condensation buildup inside pump. Minimizeknocking by partially closing valve.

39. Open GAS BALLAST valve V17 abouttwo turns to achieve steady state opera-tion. Minimize knocking by adjustingclockwise or counterclockwise as appli-cable.

Test stand VACUUM gauge indicates 100microns or less within 5 minutes.

7, 13.

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(Table 5-10)

40. Allow time for stabilization. VACUUM meter M-4 (57) indicateswithin approximately 25 microns of teststand VACUUM gauge within 30minutes.

8.

41. Turn test stand power switch off anddisconnect test stand electrical powerconnector.

Use two wrenches when loosening or tightening fittings to avoid stressing plumbing system. Failure tocomply may cause equipment damage.

42. Set TGS-1 VACUUM PUMP switch OFF,remove test stand vacuum gauge trans-ducer from test bench fitting, and reinstallcap (67) on fitting.

43. Set VACUUM PUMP switch TGS-1 on. VACUUM meter M-4 (57) indicates 100microns or less within 5 minutes.

7, 13.

Mercury height is about equal in bothlegs of manometer and are opposite zeroon scale.

10.

44. Set VACUUM PUMP switch to OFF.

45. Connect reclaimer system to valve V13(52) and set cylinder heater switch TGS-3to ON.

46. Position CYLINDER HEATER to ON.

NOTE

Loosen two thumbscrews on photo detector assembly sight-glass to ensure assembly moves freely.

47. Using scale in back of refrigerant sighttube, position photo detector scanners sopointers are 11.25 inches apart. Tightenthumbscrew firmly against rod.

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5-24



(Table 5-10)

NOTE

Perform steps 48 through 60 only if scanner units have been replaced or if faulty scanner issuspected.

48. Open valves V6 (82), V7 (78) and V13(52) 1-1/2 turns from closed position.Open LIQUID valve on refrigerantcylinder. Ensure in-line valve is fullyopen.

NOTE

As measuring tube fills, valve V13 will vent freon. Reclaimer must be operated to capture escapingvapor. Periodically, valve V13 must be fully closed to assess refrigerant level in tube. If level nolonger rises and has not reached PD-1, reset RSS-1 to fill and reopen valve V13 as required to filltube.

49. Momentarily set REFRIGERANTMEASURING TUBE selector switchRSS-1 to FILL.

Refrigerant rises in sight glass to photodetector. REFRIGERANT F indicator ONwhile measuring tube is filling.

11, 12.

50. When refrigerant liquid level reachesupper level sensor PD-1 on measuringtube shut valve V13 and shut downreclaimer system.

RSS-1 FILL light extinguishes and freonlevel stops rising at PD-1.

51. Turn TGS-2 (PANEL POWER SWITCH)to OFF.

52. Inside cabinet, disconnect P104 (Figure5-1, 56) on top of control panel. Pushcable through opening to front of cabinetand plug it into SKAN-A-MATIC tester.

53. Remove controller PEC-1 (56) from J102on top of control panel and plug it intoSKAN-A-MATIC tester.

54. Plug tester into J3 and turn on both testerswitch and CB1.

55. Slide upper photo detector scanner tolocation above refrigerant level in sightglass.

SKAN-A-MATIC tester VAPOR indicatorcomes on.

Faulty controllerPEC-1 or detectorPD-1; replace faultycomponent.

56. Slide scanner to location below refrig-erant level.

SKAN-A-MATIC tester LIQUID indicatorcomes on.

Faulty PEC-1 orPD-1; replace faultycomponent.

T.O. 33D9-17-89-1

5-25



(Table 5-10)

57. Turn off SKAN-A-MATIC tester; reinstallPEC-1 and reconnect P104 to top ofcontrol panel.

58. Repeat steps 50 through 54 with lowerphoto detector scanner P103 andcontroller PEC-3 (55) from J101.

Faulty PEC-3 orPD-3; replacecomponent.

59. Turn off SKAN-A-MATIC tester; reinstallPEC-3 and reconnect P103 to top ofcontrol panel.

60. Turn off CB1.

61. Turn TGS-2 (PANEL POWER SWITCH)to ON.

NOTE

If steps 48 through 60 were performed, omit steps 62 through 65.

62. Using scale in back of refrigerant sighttube, position photo detector scanners sopointers are 11.25 inches apart. Tightenthumbscrew firmly against rod.

Photo detector assembly should slidefreely on sight-gauge.

63. Open valve V6 (82), V7 (78), and V13(52) 1-1/2 turns from closed position.Open LIQUID valve on refrigerantcylinder.

Liquid eye and cylinder pressure gaugeindicate refrigerant supply.

NOTE

As measuring tube fills, valve V13 will vent freon. Reclaimer must be operated to capture escapingvapor. Periodically, valve V13 must be fully closed to assess refrigerant level in tube. If level nolonger rises and has not reached PD-1, reset RSS-1 and reopen valve V13, as required, to fill tube.

64. When CYLINDER HEATER light goesout, momentarily set REFRIGERANTMEASURING TUBE selector switchRSS-1 to FILL.

Refrigerant rises in sight glass to level ofupper photo detector. REFRIGERANT Findicator ON while measuring tube isfilling.

11, 12.

65. When refrigerant liquid level reachesupper level sensor PD-1 on measuringtube, shut valve V13 and shut downreclaimer system.

RSS-1 FILL light extinguishes and freonlevel stops rising at PD-1.

66. Set MEASURE TUBE HEATER switchTGS-4 to ON. Set CYLINDER HEATERto OFF.

MEASURING TUBE HEATER indicatorcomes on.

14.

T.O. 33D9-17-89-1

5-26



(Table 5-10)

67. Using vacuum bottle, connect self-sealingrefrigerant hose to test benchEVACUATE/REFRIGERANT CHARGEand vacuum bottle liquid valve and openvalve.

68. Set selector switch RSS-2 to EVACUATEand set vacuum pump switch TGS-1 toON. Wait until vacuum is less than 300microns. Adjust GAS BALLAST valve asnecessary to obtain vacuum.

EVACUATE indicator NLT-9 comes on.Pressure stabilizes at less than 300microns.

13.

69. Verify that pointer of upper photodetector scanner is even with top ofrefrigerant column in sight tube glass. Ifrequired, reposition scanners withoutchanging space between them.

NOTE

Verify MEASURING TUBE HEATER indicator extinguishes before proceeding.

70. Set selector switch RSS-2 to CHARGE. CHARGE indicator NLT-11 on.

71. Set TGS-1 VACUUM PUMP switch toOFF.

72. Momentarily set REFRIGERANTMEASURING TUBE switch toCHARGE.

REFRIGERANT MEASURING TUBE Cindicator comes on during charge. Refrig-erant level in sight glass drops to lowerphoto detector scanner within 45 to 60seconds and stops.

4, 13, 15.

73. When refrigerant level in measuring tubedrops to lower photo detector PD-3 onmeasuring tube and RSS-1 C indicatorextinguishes, close LIQUID valve onvacuum bottle.

Failure to set REFRIGERANT MEASURING TUBE HEATER switch to OFF when measuring tube isnot in filled condition will overheat and damage measuring tube assembly.

74. Set REFRIGERANT MEASURINGTUBE HEATER switch to OFF.

T.O. 33D9-17-89-1

5-27



(Table 5-10)

75. Set CYLINDER HEATER, PANELPOWER, 60 HZ POWER switches CB1and CB4 to OFF and close LIQUID valveon refrigerant cylinder.

76. Close valve V13, remove reclaimersystem, and recap valve V13.

Table 5-6. Power Troubleshooting

Trouble Probable Cause Remedy

120/208 volts of power is present inside test bench. Serious shock hazard exists when panels are removed.Failure to comply could cause personnel injury.

1. Indicators DS1, DS2,DS9 through DS15 failto come on.

1. Internal failure of indi-cator assembly, unlessmultiple failure.

a. Turn off power and disconnect bothpower cables.

b. Unsolder indicator leads, loosen nutbehind panel, and remove front knurlednut and indicator.

c. Install new indicator.

2. Wiring or switchfailure.

a. Check continuity per FO-4 with powerdisconnected. Replace switch or repairwiring as required.

3. Input power filterfailure.

a. With power disconnected, removeprotective cover from filter (Figure 5-1,2 and 3).

b. Apply power and check for 120 Vacbetween neutral and each phase.

c. Disconnect power and replace filter ifrequired.

d. Repeat step b if filter was replaced.

e. Disconnect power and reinstall cover.

2. Missing or erratic phaseA, B or C as measuredon J1 or indicated on400 Hz meters.

1. PHASE MONITORswitch S4 or relatedwiring.

a. Check continuity per FO-4 with powerconnected. Replace S4 or repair wiringas required.

T.O. 33D9-17-89-1

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Table 5-6. Power Troubleshooting - Continued


2. -Cont

2. VOLTAGE CONTROLvariable transformer T1.

a. With power disconnected, test eachtransformer (7) section for control usingmultimeter across terminals 3, 4, and 3,5.

b. If a transformer section continuity isopen or erratic because of wear, replacetransformer.

c. If S4 and T1 are good, isolate wiringfault to J1 or panel meter and repair asrequired.

3. 400 Hz POWER metersfaulty or out ofadjustment.

1. VOLTAGE M9 orFREQUENCY M8meter.

a. Remove window from front of meter byraising edge with small screwdriver andsliding out. Adjust screw in upper right-hand corner. Slide window back inplace.

b. If adjustment is not effective, replacemeter. See Paragraph 5.4.3.

2. AMPERAGEmeter/transducerM10/T2.

a. Adjust screw on current transformer T2transducer (19).

b. If adjustment is not effective, replacemeter M10 and transducer T2.

4. Power supply modulePS1 or PS2 out oftolerance.

1. Complete absence ofoutput voltage on bothPS1 and PS2 indicateswiring or CB3 fault.

a. Disconnect power and check continuity.Repair wiring or replace CB3 asrequired.

2. Output voltage of PS1or PS2 present but outof adjustment.

a. With power applied, adjust the appro-priate pod on PS2 for its proper voltage.Adjust pod A for +5.3 (±0.02) Vdc, podB for +15.0 (±0.1) Vdc, and for pod Cfor -15.0 (±0.1). Adjust the pod on thebottom of PS1 for +12.0 (±0.1) Vdc.

b. If adjustment is not effective, turn offall power and replace power supplymodule.

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5-29

Table 5-7. Control Valve Driver Circuit Troubleshooting


120/208 volts of power is present inside test bench. Serious shock hazard exists when panels areremoved. Failure to comply could result in personnel injury.

CONTROL VALVE switch S3 must be set correctly before connecting control valve and operatingOPEN/CLOSE switch S2. Damage to valve and test bench will occur.

1. LED indicators notcoming on whendriving circuitsoperate.

1. Individual LEDfailure indicates faultyLED, wiring ordriving signal

a. Turn off all power and replaceprinted circuit board in electronicenclosure (Figure 5-1, 20). Faultisolate LEDs, wiring, andswitches S2 and S3 meter. Repairas required.

b. If LED replacement is required,tag wires and unsolder. Removenut and lockwasher from rear andpull LED from front. Install newLED using care to solder wires tocorrect pins.

2. Waveforms incorrectduring checkout.

1. Driving circuits onprinted circuit boardfailed.

a. With power applied, adjust theappropriate pod on PS2 for itsproper voltage. Adjust pod A for5 Vdc reading, pod B for +15Vdc reading, and pod C for -15Vdc reading; adjust the pod onthe bottom of PS1 for the proper12 Vdc reading.

3. LEDs and waveformsokay but control valvenot operating.

1. Faulty control valveor wiring.

a. Try different control valve andfault isolate wiring as applicable.

T.O. 33D9-17-89-1

5-30

Table 5-8. Coolant System Troubleshooting


NOTE

Refer to component replacement procedures for tubing fittings and for digital panel meters.

1. COOLANTPUMP indicatorsfail to come on orcoolant pump failsto run.

1. Indicator assemblyfailure unless bothare out.

a. Turn off CB1 and replace indicator per powertroubleshooting table.

b. Fault isolate wiring and COOLANT PUMPswitch S1 per FO-4.

2. COOLANTPUMP switch ifboth indicators areout and pump isnot running.

a. Fault isolate wiring and S1.

3. Coolant pump ifindicators are onbut pump is notrunning.

a. Turn off CB1, drain coolant tank, and replacecoolant pump and motor assembly (Figure 5-1,29).

2. Coolant flow andpressure checkoutfailure.

1. Coolant filterelement clogged.

a. Turn off pump, drain tank, disconnect ringnut,and lower part of filter housing (30), andremove filter element.

b. Examine element and housing. Clean out filterhousing, and install new element if required.

2. Valves V2 (41),V3 (42) or trans-ducers MT5 (31),RT2 (35) clogged.

a. Disconnect and examine for obstruction.

3. Coolant pumpdogged or worn.

a. Remove pump, and replace or clean asrequired.

T.O. 33D9-17-89-1

5-31

Table 5-8. Coolant System Troubleshooting - Continued


3. COOLANTRETURNPRESSURE meterM4 checkout fails.

1. Meter M4 out ofadjustment.

a. Remove window from front of meter byraising end with small screwdriver and slidingout.

b. If meter does not indicate within 0.0 (±0.5)psig, adjust lower screw in right end of meter.

c. If meter does not indicate within 15.0 (±0.5)psig, adjust upper screw in right end of meter.

d. Reinstall window.

2. Meter M4 ortransducer MT2faulty.

a. Turn off CB1, and replace M4 or MT2 (36) asrequired.

4. COOLANTSUPPLYPRESSURE meterM7 checkout fails.


a. Same as remedy for COOLANT RETURNPRESSURE meter M4.

2. Meter M7 ortransducer MT3faulty.

a. Turn off CB1, and replace M7 or MT3 (12) asrequired.

NOTE

For PRI-3 type meter use steps 5 (1a thru d) and for MR1000 type meter use steps 5 (1e thru h).

5. COOLANTRETURN FLOWmeter M5checkout fails.

1. Meter M5, linear-izer A2 or trans-ducer MT5 faultyor out of calibra-tion.

a. Turn off CB1, and remove M5, A2 (37) andMT5 (31). Do not adjust units or remove tags.Install replacement M5, A2, and MT5 as acalibrated set having matching tag numbers.Leave tags attached.

b. Remove window from front of meter byraising end with small screwdriver and slidingout.

c. Set internal right-hand switches No. 7, 8, 9, 10to up, down, up, down positions, respectively.Do not disturb left-hand switches, right-handswitches No. 1 through 6, or adjustmentscrews.


e. Turn off CB1, and remove M5, A2(37) andMT5(31). Do not adjust units or remove tags.Install replacement M5, A2, and MT5 as acalibrated set having matching tag numbers.Leave tags attached.

T.O. 33D9-17-89-1

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Table 5-8. Coolant System Troubleshooting - Continued


5. - Cont f. Refer to FO-4 during wiring connections.Connected wire marked M5(5) to pin 5 onmeter. Connected wire marked M5(-) to pin 8on meter.

g. Remove two wires marked M5(15) fromconnector plug and install on pin 11 of meter.

h. Remove two wires marked M5(5) fromconnector plug and install on pin 12 of meter.

6. COOLANTRETURNTEMPERATUREmeter M3checkout fails.

1. Meter M3 orsensor RT2 faultyor out of calibra-tion.

a. Turn off CB1, and remove M3 and RT2. (35).Install replacement M3 and RT2 as a cali-brated set having matching serial numbers.

7. COOLANTSUPPLYTEMPERATUREmeter M6checkout fails.

1. Meter M6 ortransducer RT3faulty or out ofcalibration.

a. Turn off CB1, and remove M6 and RT3. (13).Install replacement M6 and RT3 as a cali-brated set having matching serial numbers.

8. COOLANTHEATERCONTROL panelA1 checkout fails.

1. Panel A1, immer-sion heater HR1,temperature sensorRT1 faulty.

a. Turn off COOLANT PUMP switch S1 and 60Hz POWER CB1.

b. Remove screws from rear cover of A1 (5) andcarefully move cover to one side.

c. Using wiring diagram FO-4, identify andisolate wires to HR1 (28) and RT1 (26), andcheck continuity.

d. Replace HR1 or RT1 if open-circuited.

e. Replace A1 if HR1 and RT1 are both good.

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Table 5-9. Air Regulation Troubleshooting


NOTE

Refer to component replacement procedures for tubing fittings and for digital panel meters.

1. Pressure regulator V16checkout failure.

1. Regulator V16 faulty. a. If indicated pressure is out oftolerance, remove and replace(Figure 5-1, 1) V16.

b. If indicated pressure is zero or ifregulator replacement does notcorrect problem, replace valve V4(11).

2. COMPRESSOR AIRRETURN PRESSUREmeter M1 checkoutfailure.


a. Remove window from front ofmeter by raising end with smallscrewdriver and sliding out.

b. If meter does not indicate within0.0 (±2.0) psig, adjust lower screwin right end of meter.

c. If meter does not indicate within100 (±5) psig, adjust upper screwin right end of meter.


2. Meter M1 or sensor MT1faulty.

a. Turn off CB1 and replace M1 orMT1 (40) as required.

3. COMPRESSOR AIRRETURN FLOW meterM2 checkout failure.

1. Meter M2, amplifier A3or transducer MT4 faulty.

a. Turn off CB1, and remove M2,A3 (34), and MT4 (39). Do notadjust units or remove tags. Installreplacement M2, A3, and MT4 asa calibrated set having matchingtag numbers. Leave tags attached.

T.O. 33D9-17-89-1

5-34

Table 5-10. Refrigeration Controls Troubleshooting


• 120-Vac power is present inside test bench. Serious shock hazard exists when panels are removed.Failure to comply could result in personnel injury.

• Do not exceed 250-psig pressure when testing PS-1 and TS-1 and make no adjustments except asspecified. PS-1 and TS-1 are safety devices to protect equipment and personnel. Failure to complymay result in personnel injury.

NOTE

Refer to component replacement procedures for tubing fittings.

1. Refrigerant cylinder pres-sure switch PS-1 ortemperature switch TS-1open before cylinder isheated and before pres-sure is applied duringcheckout.

1. PS-1, TS-1 or wiringfaulty.

a. Turn off CB4 and remove coverfrom PS-1 (Figure 5-1, 74). Loosencover screws of electrical box andopen to expose TS-1 (75) on bandheater. Using multimeter, isolateopen circuit.

b. If TS-1 or PS-1 is open circuited,replace it.

c. If neither TS-1 nor PS-1 is open,fault isolate wiring per FO-4 andrepair as required.

2. Pressure switch PS-1 outof adjustment or faulty.

1. PS-1 out of adjustment. a. Attempt to adjust PS-1 to openwithin range of 126 to 150 psig,using adjustment screws on PS-1and pressure gauge on nitrogencylinder.

2. If adjustment attempt isnot successful, PS-1 isfaulty.

a. Remove and replace entire PS-1assembly.

3. Pressure switch PS-2 outof adjustment or faulty.

1. PS-2 out of adjustment. a. Turn off CB4 and remove coverfrom PS-2 (54). Using 1/4 wrench,turn adjusting nut on top of switchassembly until signal indicator onswitch is fully up. Nut will turneasily until it reaches stop; do notforce.

b. Apply nitrogen pressure, and adjustregulator for 160 psig indication ontest stand.

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Table 5-10. Refrigeration Controls Troubleshooting - Continued


3. -Cont

c. Connect multimeter acrossterminals of PS-2.

d. Back off signal adjusting nut untilswitch closes, as indicated onmultimeter.

e. Change nitrogen pressure andcheck that switch closes withincreasing pressure at 160 psigmaximum and switch opens withdecreasing pressure at 145 psigminimum.

2. PS-2 faulty. a. Replace PS-2.

4. Fault neon panel indica-tors NLT-1 thru NLT-11,faulty switch or faultywiring.

1. Internal resistor failed. a. Replace neon indicator assembly.

2. Damaged wire, looseterminals or switchfailure.

a. Fault isolate per FO-4 and repair asrequired.

5. 5 AMP FUSE indicatoron.

1. Fuse failed. a. Replace fuse.

2. Short to ground in refrig-erant fill and chargecontrol circuits.

a. With power disconnected, use sche-matic FO-4 and multimeter toisolate fault. Repair as required.

6. Vacuum pump does notrun.

1. Loss of electrical powerif VACUUM PUMPindicator not on.

a. Disconnect power and fault isolatewiring and VACUUM PUMPswitch TGS-1 at J112 (58) pins 2and 3.

2. Vacuum pump motorfailure.

a. Remove vacuum pump motor (70).

b. Install replacement pump motorand adjust belt to flex the thicknessof the belt with normal thumb pres-sure midway between pulleys.

7. Vacuum failure duringvacuum pump test.

1. Solenoid valveSOL-V/V8 not open orSOL-P/V9 not closed orpump is not functioningproperly if no vacuum isindicated.

a. Disconnect power and fault isolatewiring and selector switch RSS-2at J111 (58) pins 3 and 4.

b. Check continuity of SOL-V coil atP111 pins 3 and 4. Repair wiringor replace SOL-V/V8 (65) asrequired.

c. Remove vacuum pump drive beltpulley guard (72) and replace beltif broken or slipping.

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7. -Cont

d. Remove and replace SOL-P/V9(63).

2. Required vacuumpressure cannot beattained.

a. Ensure tubing fittings are tight.

b. If vacuum pump oil contaminationis suspected, drain oil. Unscrewdischarge mist eliminator tank frompump and pour one pint superX/Flushing High Vacuum oil intodischarge opening of pump casting.Reinstall tank and run pump about2 minutes. Remove tank, add 1/3pint oil and reinstall tank.

c. Replace vacuum pump.

8. VACUUM meter M-4(57) not within 25microns of test stand.

1. VACUUM meter out ofadjustment.

a. Turn off CB4.

b. Remove rear cover of programcontrol center (58) and removemeter retaining nuts (do notremove wires). Slide meter outfront of panel.

c. Turn on CB4.

d. Turn adjustment screw on top ofmeter until indication is within 25microns of test stand indication.

e. Turn off CB4.

f. Reinstall meter and cover.

g. Turn on CB4.

2. VACUUM meter faulty. a. Turn off CB4 and replace meter.

9. REFRIGERANTPRESSURE gauge out ofcalibration.

a. Remove and replace gauge.

10. Manometer gauge (86)mercury columns notabout equal height at 100microns vacuum.

1. Manometer faulty. a. Remove scale from front ofmanometer, and have tube sealingmechanism ready to install. (SeeChapter 3).

b. One person hold manometer and asecond person disconnect tubefitting and two mounting nuts inrear. Remove manometer frompanel, keeping U-tube upright.

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10. -Cont

c. Remove wingnut, gauge head, andtwo neoprene gaskets frommanometer.

d. Slowly insert plunger end ofsealing mechanism into right-handleg of U-tube until it barelycontacts mercury.

e. Grip threaded end of mechanismand turn down nut until expansionwasher at plunger end makes verysnug fit in tube.

f. Carefully install washer, coilspring, gauge head, and wingnut onmanometer.

g. On replacement manometer, reversethe removal procedure, again beingcareful when removing sealingmechanism and in keeping U-tubeupright.

h. Store tube sealing mechanism intop drawer of test bench.

11. Refrigerant measuringtube will not fill.

1. If REFRIGERANT Findicator does not comeon, failure is electrical.

a. Fault isolate by replacing thefollowing plug-in parts:

1. PEC-1 (56) at J102 ontop of control panelassembly (58). Refer tocheckout withSKAN-A-MATIC tester.

2. Relay CR-F (61) withincontrol panel assembly.

b. With power off, fault isolateREFRIGERANT MEASURINGTUBE switch RSS-1 and relatedwiring.

2. If REFRIGERANT Findicator comes on,failure is in refrigerantline.

a. Verify refrigerant is indicated inliquid eye on cylinder and thatvalves V6 (82), V7 (78), and V13(52) are open.

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11. -Cont

b. If measuring tube partially fills andREFRIGERANT PRESSUREgauge indicates operating pressureof about 125 psig, failure is insolenoid valve SOL-E/V12 (87).Check continuity of solenoid atP105 (58) pins 3 and 4. Repairwiring, if required, or remove andreplace solenoid valve.

c. If no refrigerant transfers tomeasuring tube and no pressureincrease registers on gauge, failureis in solenoid valve SOL-F/V11(79). Check continuity at P109 (58)pins 1 and 4. Repair wiring, ifrequired, or remove and replacesolenoid valve.

12. Refrigerant measuringtube overfills.

1. Photoelectric devicefailure.

a. If upper photo detector scannerPD-1 (Figure 4-3, 4) light beam isvisible, photoelectric controllerPEC-1 (Figure 5-1, 56) at J102.

b. If PD-1 light beam is not visible orif PEC-1 did not correct problem,replace PD-1 at J104 (56) and onsight glass.

c. Refer to checkout withSKAN-A-MATIC tester.

d. Fault isolate and repair wiring.

13. Evacuation of pressurevessel fails.

1. System leaks if unable toattain required vacuum.

a. Check hose connections and tightenfittings if required.

2. SOL-P/V9 not open ifvacuum occurs tooquickly.

a. Check continuity of SOL-P/V9 (63)at P110 (58) pins 1 and 2. Repairwiring, if required, or remove andreplace solenoid valve.

14. Refrigerant does nottransfer from measuringtube when charge cycleis attempted.

1. If REFRIGERANT Cindicator does not comeon, failure is electrical.

a. Verify MEASURING TUBEHEATER indicator cycled from ONto OFF before charge attempt andthat function selector switch is setto CHARGE.

b. Fault isolate by replacing thefollowing plug-in parts:

1. PEC-3 at J101 (55).

2. Relay CR-C (60).

3. Relay CR-H (59).

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14. -Cont

c. With power off, fault isolateREFRIGERANT MEASURINGTUBE switch RSS-1, functionswitch RSS-2, and related wiring.

d. Disconnect a wire from eachmeasuring tube heater element andcheck continuity through it.Replace element if open circuited.See Paragraph 5.4.2.

2. If REFRIGERANT Cindicator does come on,failure is in solenoidvalve SOL-C/V10.

a. With power off, check continuity ofSOL-C at P109 (58) pins 1 and 3.

b. Repair wiring, if required, orremove and replace solenoid valve(81).

15. Refrigerant transfer doesnot stop at lower photodetector during chargecycle.

1. Photoelectric devicefailure.

a. If lower photo detector PD-3 lightbeam is visible, replace photoelec-tric controller PEC-3 at J101 (55).

b. If light beam is not visible or ifPEC-3 did not correct problem,replace PD-3 at J103 (55) and onsight glass.

c. Refer to checkout withSKAN-A-MATIC tester.

d. Fault isolate and repair wiring.

16. Pressure vessel weightincorrect after chargetest.

a. Contact technical engineering.

17. No evidence of refrig-erant cylinder heating.Blanket should feel warmand REFRIGERANTPRESSURE gauge indi-cation should rise toabout 125 psig.

1. Cylinder heater faulty. a. Turn off CB4, and check continuityacross plug P108 (58) pins Y andZ. (Pin Y is crossways, and pin Xis next to Y counterclockwise whenviewing P108 pins).

b. If open circuited, open electricalbox on heater assembly, disconnectwires in box, unsnap, and removeband heater.

c. Install and assemble replacementheater.

2. CYLINDER HEATERswitch TGS-3 or wiringfaulty.

a. Fault isolate TGS-3 and wiring.Repair as required.

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18. CYLINDER HEATERindicator does not cycleoff during periods whenrefrigerant valve is closedand heater switch is on.Cylinder is hot.

1. Thermostat temperatureswitch TS-1 not opening.

a. Turn off CB4.

b. Loosen cover screws and removecover of box to access TS-1 (75).

c. Replace TS-1.

5.3 SERVICE.

Routine and periodic servicing is required of the coolant supply, coolant filter, refrigerant supply, and vacuum pump.

5.3.1 Coolant Supply and Filter Servicing. It is required to replenish the coolant in the storage tank to 3 (±1) inchesfrom the top and to periodically remove and clean/replace the filter element. Place a suitable container under the coolant tankpetcock and drain water. Access the filter element by removing the ringnut and lower filter housing (Figure 5-1, 30). Examinethe filter element. If damaged, discard and replace with a new filter element. If undamaged, clean the filter element with anultrasonic cleaner (Table 2-1) as follows:

Ultrasonic cleaning detergent is toxic and hazardous. Wear approved eye and handprotection. Failure to comply could result in personnel injury.

a. In a clean container, mix four liters of distilled water with 100 milliliters of Micro 10 ultrasonic cleaningconcentrate detergent or equivalent. Stir to thoroughly dissolve concentrate.

Filter element and/or ultrasonic cleaner may be contaminated with sodium chromatesolution. Wear approved eye and hand protection. Failure to comply may result in personnelinjury.

b. Wipe inside of ultrasonic cleaner with a clean, dry cloth to remove dust or impurities before use.

c. Place filter element into ultrasonic cleaner.

d. Pour cleaning solution into the ultrasonic cleaner until filter element is covered. Place lid on cleaner.

e. Plug ultrasonic cleaner into a 110-volt outlet and set selector switch to ON.

f. Allow ultrasonic cleaner to operate a minimum of 15 minutes.

g. Set selector switch to OFF and unplug unit.

NOTEWhen cleaning extremely dirty filter elements, additional cleaning may be required. Discardfilter element if not clean after second additional cleaning.

h. If additional cleaning is required, proceed to step a.

i. Remove filter element from ultrasonic cleaner.

j. Add 100 milliliters of ultrasonic cleaning concentrate to original solution and stir to thoroughly dissolveconcentrate.

k. Place filter element into ultrasonic cleaner.

l. Repeat step d, step e, and step f.

m. Remove filter element from ultrasonic cleaner and rinse with distilled water.

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Solution in ultrasonic cleaner may be contaminated with sodium chromate solution. Wearapproved eye and hand protection. Failure to comply may result in personnel injury.

NOTEResidual stains on the filter element do not affect the operational capability as long as theelement passes the flow checkout procedure.

n. Empty solution from ultrasonic cleaner into a container suitable for disposal of hazardous waste.

o. Rinse ultrasonic cleaner with distilled water empty into container suitable for disposal of hazardous waste. Drywith a clean cloth.

5.3.2 Refrigerant Supply Service. The refrigerant supply must be replenished if refrigerant is not visible in the liquideye on the cylinder when the LIQUID valve is open.

NOTEThe supply tank should be connected with a low-loss refrigerant hose which contains anintegral shutoff valve at the end connected to the tank.

a. Close both the liquid and vapor valves on the tank.

b. If the tank is connected with a low-loss refrigerant hose with a shutoff valve, go to step d. If the tank is notequipped with such a hose, close valve V7.

NOTEVenting of the refrigerant vapor contained in the hose connecting the tank to the test benchis allowable under section 608 of the Clean Air Act. However, any nonshutoff-typerefrigerant hoses should be changed to low-loss type hoses to minimize refrigerant ventingduring future tank replacements.

c. Slowly loosen the hose connection on the tank. Allow the pressure to bleed off before disconnecting the hose.

d. Close the shutoff valve at the end of the hose connecting the tank to the test bench.

e. Remove and replace refrigerant supply tank.

5.3.3 Vacuum Pump Service. Contaminated oil is the most common cause of poor performance, and the contaminationis controlled to a great extent by gas ballast operation. Avoid extended operation with the GAS BALLAST valve closed. Oilcan be visually checked by draining a small quantity into a clean container and inspecting for solid or liquid contaminants.Periodically, and when found to be contaminated, the oil must be changed. When servicing the vacuum pump, also make thefollowing inspections:

a. Remove the guard (Figure 5-1, 72) and inspect the belt for wear and adjustment. Belt should flex about the thick-ness of belt with normal thumb pressure midway between pulleys.

b. Turn the pump clockwise by hand. Observe no mechanical interference, but an increase in required force at anglewhere discharge occurs. If required force indicates cylinder is flooded, causing a hydraulic lock, rock the pumppulley by hand to force the oil out. The pump will flood if the vacuum break valve (SOL-B, 68) fails to open.

c. When pump is operating, observe that oil is about midway in sight glass (71) when inlet pressure is low and thatoil level changes with large changes in vacuum indications. If there are no discernible oil level changes, oil pas-sages within the pump may be obstructed.

5.3.3.1 Changing the Oil. Open both drain valves (73), remove the filler plug and oil mist eliminator (69), and removethe drive belt guard. After the oil drains, turn the pump pulley clockwise a few turns by hand to clear all oil from cylinder.Close the drain valves. The oil capacity of the pump is 1-1/3 pints or 21-1/3 ounces. Pour about seven ounces through fillerplug hole and the remainder through the hole from which the oil mist eliminator was removed. Check that filler plug andgasket are clean and in good condition, and reinstall plug with gasket and the oil mist eliminator. If oil was badlycontaminated, it may be necessary to flush the pump by changing the oil one or more additional times with a short operatingperiod between changes.

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5.3.3.2 Oil Mist Eliminator. Pump back-pressure of 4 to 6 psig, as measured at the mist eliminator inlet or pump fillerplug, is an indication of clogged filter element. Pump motor heating is another indication. If mist is being discharged from misteliminator, the filter element or gasket may be ruptured. However, periodic replacement of the filter element greatly reducesthe probability of these failures occurring. When required, remove the top half of the mist eliminator, clean and inspecthousing, replace filter element with a new one, and reassemble using a new gasket.

5.4 COMPONENT REPLACEMENT.

The removal and installation of test bench components requires use of common hand tools and common shop skills. Specialprocedures in this section apply to components with hidden fasteners and to components requiring sealing.

5.4.1 Tubing Fittings. Before assembling tubing components, inspect all parts for damage, wear, thread condition, andcleanliness. Reject unsatisfactory parts. Wrap male pipe threads of coolant and air fittings with Teflon tape. On refrigerant andvacuum pipe threads, first apply high vacuum sealant, then wrap with two layers of Teflon tape, and apply sealant over thetape. Assemble all straight thread fittings using dry lubricant or water.

5.4.2 Measuring Tube Heater Replacement. Before installing immersion heater elements into the refrigerantmeasuring tube baseplate (83), apply adhesive to the heater element threads.

5.4.3 Digital Panel Meters. The digital type meters contain either one or two printed circuit boards which protrude outthe rear for cable connection. The two flowmeters have screw terminals and all other meters use cable connectors. All exceptthe flowmeters fasten to the panel by a screw-clamp arrangement accessible behind the front window. The flowmeters fastento the panel with mounting brackets and screws at the rear. To remove a flowmeter, first electrically disconnect it at the rear.Then remove the bracket screw and the bracket at each end. To remove any other meter, pull the cable connector(s) off therear, and then on the front slide the window out by first carefully lifting one end with a small screwdriver. Loosen the mountingscrew at each end and remove the meter from the panel. Reverse the procedure to install a meter.

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FO-1. Electrical Schematic - Left Side of Test Bench

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FO-2. Plumbing Schematic

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FO-3. Electrical Schematic - Right Side of Test Bench

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FO-4. Wiring Diagram

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FO-5. Electronic Enclosure Schematic

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FO-6. Airflow Checkout Connections

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